Method and system for order fulfilment

ABSTRACT

A method of fulfilling an order comprising at least one product is provided. The method includes receiving an order comprising at least one product, determining a suitable case from a plurality of available cases for holding the at least one product, said determining being a function of one or more characteristics of each product of the at least one product and one or more characteristics of the plurality of available cases; forwarding information identifying the suitable case to a case former; providing a case blank corresponding to said suitable case to said case former; erecting a suitable case from said case blank corresponding to said suitable case with said case former; and prior to the loading said suitable case with said at least one product, labelling said suitable case with at least one label.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/230,979 filed on Dec. 21, 2018 which is a continuation of U.S. patentapplication Ser. No. 14/644,842 filed on Mar. 11, 2015, which claimspriority from U.S. Provisional Patent Application Ser. No. 61/951,263filed on Mar. 11, 2014. The contents of the aforementioned applicationsare incorporated by reference herein.

This application also incorporates by reference herein International PCTPatent Application Serial No. PCT/CA2013/000245 filed on Mar. 15, 2013and U.S. Provisional Patent Application Ser. No. 61/637,665 filed onApr. 24, 2012, in their entireties.

FIELD OF THE INVENTION

The present invention relates generally to methods and systems for orderfulfilment such as order fulfilment of products ordered by customers. Italso relates to systems and methods for erecting cases from case blanks.

BACKGROUND

Containers are used to package many different kinds of products. Oneform of container used in the packaging industry is what is knowngenerically as a “box” and it can be used to hold various products andsometimes other boxes containing products. Some in the packagingindustry refer to boxes used to package one or more products as“cartons”. Also in the industry there are containers/boxes that areknown by some as “cases”. In this patent document, including the claims,the words “case”, “cases”, “carton”, “cartons” “container” and“containers” are used interchangeably to refer to boxes, cartons, traysand/or cases and the like that can be used to package any type of itemsincluding products and other cartons.

Cases come in many different configurations and are made from a widevariety of materials. However, many cases are foldable and are formedfrom a flattened state (commonly called a carton blank). Cases may bemade from an assortment of foldable materials, including but not limitedto cardboard, chipboard, paperboard, corrugated fibreboard, other typesof corrugated materials, plastic materials, composite materials, and thelike and possibly even combinations thereof.

Cases can be used to fulfil an order initiated by a customer for one ormore products by obtaining each product from one or more locations in astorage facility such as a warehouse, loading the product(s) into acase, sealing the case, and then shipping the loaded case to a customer.

However, there are many obstacles to providing efficient methods andsystems to fulfil customer orders, particularly where it is desirable tobe able to fulfil orders for a large number of customers that may eachhave orders for a wide range of different kinds and/or number ofproducts.

Accordingly, an improved method and system of product fulfilment isdesirable.

SUMMARY

According to one aspect of the present invention there is provided amethod of fulfilling an order, the order comprising at least oneproduct, the method comprising: receiving an order comprising at leastone product; determining a suitable case from a plurality of availablecases for holding the at least one product, the determining being afunction of one or more characteristics of each the product of the atleast one product and one or more characteristics of the plurality ofavailable cases; forwarding information identifying the suitable case toa case former; providing a case blank corresponding to the suitable caseto the case former; erecting a suitable case from the case blankcorresponding to the suitable case with the case former; and prior toloading the suitable case with the at least one product, labelling thesuitable case.

According to another aspect of the present invention there is provided amethod of fulfilling an order, the order comprising a plurality ofproducts, the method comprising: receiving an order comprising aplurality of products; determining a plurality of suitable cases fromthe plurality of available cases for holding the plurality of products,the determining being a function of at least one characteristic of eachthe product of the plurality of products and of at least onecharacteristic of the plurality of available cases; forwardinginformation identifying the plurality of suitable cases to at least onecarton former; providing case blanks corresponding to each of theplurality of suitable cases to the at least one case former; the atleast one carton former erecting the plurality of suitable cases fromthe case blanks corresponding to each of the plurality of suitable caseswith the one or more case formers; prior to loading each of the suitablecases formed from the case blanks with the one or more case formers,labelling each of the suitable cases.

According to another aspect of the present invention there is provided asystem for fulfilling an order, the order comprising at least oneproduct, the at least one product having a product characteristic, thesystem comprising: an order fulfilment processor; a first case blankmagazine and a second case blank magazine, the first and second caseblank magazines each holding at least one case blank, with the at leastone case blank in the first magazine and the second magazine each havinga case blank characteristic; a carton former operable to erect a casefrom a case blank held in either of the first and second case blankmagazines; a case blank feeding apparatus operable to selectively feed acase from each of the first case blank magazines to the case former; alabelling device operable to label a case blank prior to loading thecase with at least one product; wherein the order fulfilment processoris operable to (a) receive an order comprising at least one product; (b)determine a suitable case for the at least one product from the at leastone case in the first and second case blank magazines as a function ofthe product characteristic of each the at least one product and the caseblank characteristic of each the at least one case blank in the firstand second case blank magazines; and (c) forward information identifyingthe suitable case to a case former; and wherein the case former isoperable to: (i) receive the information identifying the suitable casefrom the order fulfilment processor: (ii) select and receive a caseblank from the case blank feeding apparatus for the suitable case fromone of the first and second magazines; and (iii) erect the suitable casefrom the case blank; and wherein the labelling device is operable tolabel the case blank of the suitable case prior to or after the caseformer has erected the suitable case from the case blank.

According to another aspect of the present invention there is provided asystem for fulfilling an order, the order comprising a plurality ofproducts, the plurality of products each having a productcharacteristic, the system comprising: an order fulfilment processor; aplurality of case blank magazines each holding a plurality of availablecase blanks, with the plurality of available case blanks in each of theplurality of magazines having a case blank characteristic; a cartonformer operable to erect a case from a case blank of each of theplurality of case blank magazines; a case blank feeding apparatusoperable to selectively feed a case blank from each of the plurality ofcase blank magazines to the case former; a labelling device operable tolabel each of the cases prior to loading each case with at least oneproduct; wherein the order fulfilment processor is operable to (a)receive an order comprising a plurality of products; (b) determine atleast one suitable case for holding the plurality of products as afunction of the product characteristic of the plurality of products andthe case blank characteristics of each of the case blank in theplurality of case blank magazines; and (c) forward informationidentifying a suitable case to a case former; and wherein the caseformer is operable to: (i) receive the information identifying asuitable case from the order fulfilment processor: (ii) select andreceive a case blank from the case blank feeding apparatus correspondingto the suitable case from one of the available case blanks in one of theplurality of case blank magazines; and (iii) erect the suitable casefrom the case blank; and wherein the labelling device is operable tolabel the case blank of the suitable case prior to or after the caseformer has erected the suitable case from the case blank.

According to another aspect of the present invention there is provided asystem for forming a container from a tubular blank comprising aplurality of panels and flaps interconnected to provide a generallyflattened tubular configuration, wherein the plurality of panelscomprise a first panel, and a second panel interconnected to the firstpanel, the second panel being rotatable relative to the first panel, thesystem comprising: (a) a plurality of magazines, each of the pluralityof magazines for storing a plurality of tubular blanks in a generallyflat configuration; (b) a case blank transfer apparatus for transferringa case blank from a selected one of the plurality of magazines to anerector head; (c) an erector head operable to received a case blank at apick up location from the case blank transfer apparatus and open thecase blank; (d) a folding and sealing apparatus; and (e) a movementsub-system having at least one movement apparatus connected to theerector head for moving the erector head along a cyclical path extendingbetween the pick up location and the folding and sealing apparatus.

According to another aspect of the present invention there is provided amethod for forming a container from a tubular blank comprising aplurality of panels and flaps interconnected to provide a generallyflattened tubular configuration, wherein the plurality of panelscomprise a first panel, and a second panel interconnected to the firstpanel, the second panel being rotatable relative to the first panel, themethod comprising: a. obtaining a selected case blank from one magazineof a plurality of magazines, each of the plurality of magazines storinga stack of tubular blanks in a generally flat configuration; b.transferring the selected case blank to an erector head; c. erecting theselected case blank with the erector head; and d. folding and sealingthe selected case blank.

Other aspects and features of the present invention will become apparentto those of ordinary skill in the art upon review of the followingdescription of specific embodiments of the invention in conjunction withthe accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

In the figures which illustrate by way of example only, embodiments ofthe present invention,

FIG. 1A is top right front perspective view of part of a carton formingsystem in accordance with an example embodiment of the presentinvention;

FIG. 1B is a schematic flow chart of the power and control sub-system ofthe part of the case forming system of FIG. 1A:

FIG. 2 is a top right rear perspective view of the carton forming systemof FIG. 1A;

FIG. 3 is a top right side perspective view of the carton forming systemof FIG. 1A;

FIG. 4 is a front schematic elevation view of the carton forming systemof FIG. 1A, but with several components omitted;

FIG. 5 is a rear schematic elevation view of the carton forming systemof FIG. 1A but with several components omitted;

FIG. 6A is a top right perspective view of a magazine sub-system;

FIG. 6B is a top right perspective view of the magazine sub-system ofFIG. 6A, but with several components omitted;

FIG. 6C is a right side elevation view of the magazine sub-system ofFIG. 6A, but with several components omitted;

FIG. 6D is a top plan view of the magazine sub-system of FIG. 6A;

FIG. 7 is a right side perspective view of the system of FIG. 1A butwith several components omitted to show the blank intake system and thetwo erector heads and movement apparatuses, and a folding and sealingapparatus;

FIG. 8 is a top right rear perspective view of the components of FIG. 7;

FIG. 9 is a top right front perspective view of the components of FIG.7;

FIGS. 10A-10E are a plan, front and side elevation views and twoperspective views, of a blank for a regular slotted case shown is agenerally flattened tubular configuration;

FIGS. 11-16 are schematic right perspective sequential views of a blankof FIGS. 10A to 10E configured in an open configuration beingsequentially processed into an erected carton;

FIGS. 17-25 and 27-29 are schematic right perspective views of system ofFIG. 1A, but showing only a single movement apparatus, erector head andsome parts of the folding and sealing apparatus, in various sequentialstages of a blank of FIGS. 10A to 10E being processed into an erectedcarton;

FIG. 26 is a rear elevation view of the components of FIG. 17;

FIG. 26A is a schematic perspective view of part of the folding andsealing apparatus of system shown in FIG. 1A.

FIG. 30 shows a top right perspective view of a first embodiment of anerector head;

FIG. 31 is a side elevation view of the erector head of FIG. 30;

FIG. 32 is a bottom right perspective view of the erector head of FIG.30;

FIG. 33 is a bottom plan view of the erector head of FIG. 33;

FIG. 34A is a top right perspective view of a second embodiment of anerector head;

FIG. 34B is a right side elevation view of the erector head of FIG. 34A;

FIGS. 35A, 35B and 35C show the erector head of FIG. 34A in variousstages of opening a blank;

FIGS. 36-44 show the erector head of FIG. 34A and a sealing apparatus invarious stages of erecting a blank and assembling it into a carton;

FIG. 45 is a schematic perspective view showing an alternativeembodiment of a carton forming system; and in particular alternateerector heads, their corresponding moving apparatus and foldingapparatus.

FIG. 46 is a plan view of a blank for a tray that may be processedaccording to some embodiments of the system.

FIG. 47 is a perspective view of a blank for an over-wrapping regularslotted case (RSC) that may be processed according to some embodimentsof the system.

FIG. 48 is a perspective view of a blank for an over-wrapping regularslotted case (RSC) that may be processed according to some embodimentsof the system.

FIG. 49 is a perspective view of an HSC case that may be formedaccording to some embodiments of the system.

FIGS. 50-52 are perspective views of an alternate folding and sealingapparatus that may be used in some embodiments of the invention.

FIG. 53 is a plan view of case former that is an alternate embodiment tothe carton/case forming system of FIGS. 1 to 44 with some components ofthe case magazines omitted for clarity

FIG. 54 is a rear right side perspective view of the case former of FIG.53.

FIG. 54A is an enlarged view of portion 54A in FIG. 54 with additionalcomponents illustrated.

FIG. 55 is a rear left side perspective view of the case former of FIG.53.

FIG. 56 is rear perspective view of the case former of FIG. 53.

FIG. 57 is a rear perspective view of part of the case former of FIG.53.

FIG. 58 is a schematic diagram illustrating an order fulfilment system.

FIG. 59 is a sample label that may be generated and used in the systemof FIG. 58.

FIG. 60 is another sample label that may be generated and used in thesystem of FIG. 58.

FIG. 61 is a sample of a case packing diagram that may be generated andused in the system of FIG. 28.

FIGS. 62A and 62B together form a schematic representation of theoperation of a system of FIG. 58.

DETAILED DESCRIPTION

With reference initially to FIGS. 1A-3, an example of a carton/caseforming system that may be used as part of a product order fulfilmentsystem is a carton/case forming system 100 (generally referred to ascarton forming system 100). Carton forming system 100 may include aframe generally referred to as frame 109. The frame 109 may haveintegrated with it a series of panels 103 that may be made from aplastic or glass and that may or may not be transparent orsemi-transparent. One or more of the panels 103 may be configured tooperate as a hinged door so that interior portions of system 100 can beaccessed. System 100 may also include a magazine 110 adapted to receive,hold and move a plurality of carton blanks 111 while in a substantiallyflat orientation. System 100 may include at least first and seconderector heads 120 a, 120 b for retrieving carton blanks from themagazine 110. Erector heads 120 a, 120 b may pick up the carton blanks111 from the magazine 110 and then manipulate the blanks in such a waythat, with the assistance of other components of system 100, the cartonblanks 111 are transformed into erected cartons.

The erector heads 120 a, 120 b may be moved by a movement sub-system.The movement sub-system may include one or more movement apparatuses.For example, erector head 120 a may be mounted to and moved by a firstmoving apparatus 115 a. Second erector head 120 b may be mounted to andmoved by a second moving apparatus 115 b. In some embodiments only asingle erector head and movement apparatus may be provided, but this mayresult in a lower production rate of erected cartons compared to whenparticularly two or possibly more, movement apparatuses and erectorheads are provided, as illustrated in the drawings.

System 100 may also include a folding and sealing apparatus generallydesignated 130, which may be configured to fold one or more flaps ofeach carton blank and provide for sealing of one or more flaps as partof the process in forming fully erected cartons. In co-operation witherector heads 120 a, 120 b, a common folding and sealing apparatus 130may be configured to handle in alternating sequence, carton blanks 111carried by both erector head 120 a and erector head 120 b. System 100may also include a carton discharge conveyor 117 for receiving andmoving away carton blanks 111 once they have been fully erected.

The structural/mechanical components of system 100 may be made from anysuitable materials. For example, frame members, and many of the partsthat make up the erector heads 120, moving apparatuses 115, many of thecomponents and parts that make up folding and sealing apparatus 130, andmagazine 110, may be made of steel or aluminium, or any other suitablematerials. Aluminum is particularly suitable for most parts. However,plates that hold the suction cups on the erector head and flanges thatmount on gearbox shafts can be made from stainless steel for strengthand hardness. Parts and components may be attached together inconventional ways such as for example by bolts, screws, welding and thelike.

An example of a scheme for the power and data/communicationconfiguration for system 100 is illustrated in FIG. 1b . The operationof the components of carton forming system 100, and of system 100 as awhole, may be controlled by a programmable logic controller (“PLC”) 132.PLC 132 may be accessed by a human operator through a Human MachineInterface (HMI) module 133 secured to frame 109. HMI module 133 may bein electronic communication with PLC 132. PLC 132 may be any suitablePLC and may for example include a unit chosen from the Logix 5000 seriesdevices made by Allen-Bradley/Rockwell Automation, such as theControlLogix 5561 device. HMI module 132 may be a Panelview part number2711P-T15C4D1 module also made by Allen-Bradley/Rockwell Automation. Itshould be noted that not all of the sensors, motors, servo motors,drives, vacuums, vacuum generators and vacuum cups described hereinafterare specifically identified in FIG. 1B.

Electrical power can be supplied to PLC 132/HMI 133, and to all thevarious servo motors and DC motors that are described further herein.Compressed/pressurized air can also be supplied to the vacuum generatorsand pneumatic actuators through valve devices such as solenoid valvesthat are controlled by PLC 132, all as described further herein. Servomotors may be connected to and in communication with servo drives thatare in communication with and controlled by PLC 132. Similarly, DCmotors may be connected to DC motor drives that are in communicationwith and controlled by PLC 132; again all as described further herein.Additionally, various other sensors are in communication with PLC 132and may (although not shown) also be supplied with electrical power.

With reference now to FIG. 10A-10E and 11A, an example of one kind oftubular carton blank 111 that can be processed by system 100 to form aregular slotted case (RSC) is disclosed. Other kinds of carton blanks,tubular carton blanks, and tubular carton blanks of different sizes canbe processed by system 100.

Each carton blank 111 may be generally initially formed and provided ina flattened tubular configuration as shown in FIGS. 10A-10E. Each blank111 has a height dimension “H”; a length dimension “L”; and a majorpanel length “Q” (see FIG. 10B). By inputting each of these threedimensions for a blank 111 to be processed by system 100, into PLC 132,PLC 132 can determine if the system 100 can process that size blankwithout the necessity for manual intervention to make an adjustment toone or more components of the system 100. If PLC 132 determines that theadjustment can be made without human intervention, the PLC 132 may makethe necessary adjustments to positions and/or movements of at least someof the components forming system 100, including the path of movement oferector heads 120 a, 120 b as the erector heads move and cycle throughtheir processing sequences.

However, in some systems 100, for some size blanks 111, PLC 132 maydetermine that human intervention of some kind is necessary to makeset-up adjustments to the positioning/orientations of at least some ofthe components of the system to enable the system to process the blankand may accordingly inform an operator of system 100.

Blank 111 may have opposed major panels A and C integrallyinterconnected to a pair of opposed minor panels B and D to form agenerally cuboid shaped blank when opened. An overlap strip of cartonblank material may be provided between panel B and panel A that can besealed by conventional means such as a suitable adhesive, to provide anoverlapping seam joint in the vicinity of “P” (see FIG. 10A). Thisoverlap may join the panels A, B, C and D into a continuous blank thatis of generally flattened tubular configuration as shown in FIG. 10A. Anumber of such blanks 111, in a flattened configuration, can bedelivered to the vicinity of system 100 that can be erected into thegenerally open tubular configuration shown for example in FIG. 11.

Also, as shown in FIGS. 10A-10E and 11, are upper side major and minorflaps E, H, L, I that are provided one side of the respective major andminor panels A-D. A second set of major and minor flaps F, G, K and Jare also provided on the opposite, lower/bottom sides of the major andminor panels A-D. However, in other embodiments, cartons having otherside panel configurations can be formed. The panels and flaps can beconnected to adjacent flaps and/or panels by predetermined fold/creaselines (shown in broken lines). These fold/crease lines may for examplebe formed by a weakened area of material and/or the formation of acrease with a crease forming apparatus. The effect of the fold lines issuch that one panel such as for example panel A can be rotated relativeto an adjacent panel such as D or B along the fold lines. Flaps may alsofold and rotate about fold lines that connect them to their respectivepanels.

As shown in FIG. 11, blank 111 may be designated with a first datum line“W1” that passes through the mid-point of the fold line between panel Dand flap K, and the mid-point of the fold line between panel B and flapJ. This datum line W1 may be determined by PLC 132 for a particularblank or group of blanks 111 to be processed, based on the input of thedimensions H, L and Q of the blanks. Blank 111 may be designated with asecond datum line “W2” that may be determined by PLC 132 and whichpasses along and is generally parallel to the fold line between panel Dand flap K, and the mid-point of the fold line between panel A and flapF. Datum W1 will be parallel to Datum W2. PLC 132 may also determine therelative position of the bottom of the erected carton as this will bealigned with a vertical datum plane passing through Datum W1 and DatumW2. Aligning the position datum W2 and of the datum plane with othercomponents in system 100 will ensure that the carton is properlypositioned during processing through system 100. Also, the verticaldistance R between datum W1 and the datum line W2 may be calculated byPLC 132. This can ensure that PLC 132 knows where it needs to positionthe erector head so that top panel A, and accordingly, datum W1 areproperly positioned throughout the processing of the blank by system100.

System 100 is able to track and modify the position of the blank 111,and in particular the vertical position of the datum line W1 of theblank as the blank moves longitudinally through system 100 and asvarious components of system 100 engage the blank 111 during itsmovements. This will ensure that the blank 111 being processed isappropriately positioned relative to the system components so that thesystem components engage the blank at the correct position on the blankduring processing of the blank.

As will be described hereinafter, carton blank 111 may be transformedfrom a generally flattened tubular configuration to an open tubularconfiguration and the flaps may be folded and sealed to form the desirederected carton configuration. The carton may be configured as a topopening carton suitable to be delivered to a carton loading conveyorwith an upwardly facing opening or with a sidewards facing openingsuitable for side loading.

Carton blanks 111 may have flaps that provides material that can, inconjunction with a connection mechanism (such as for example withapplication of an adhesive, sealing tape or a mechanical connection suchas is provided in so-called “Klick-lok™” carton blanks) interconnectflap surfaces, to join or otherwise interconnect, flaps to adjacentflaps (or in some embodiments flaps to panels), to hold the carton inits desired erected configuration.

Carton blanks 111 may be made of any suitable material(s) configured andadapted to permit the required folding/bending/displacement of thematerial to reach the desired configuration. Examples of suitablematerials are chipboard, cardboard or creased corrugated fiber-board. Itshould be noted that the blank may be formed of a material which itselfis rigid or semi-rigid, and not per se easily foldable but which isdivided into separate panels and flaps separated by creases or hingetype mechanisms so that the carton can be erected and formed.

Turning now to the components of system 100, various specificconstructions of a suitable magazine 110 might be employed in system100. With particular reference now to FIG. 3, FIGS. 6a-d , and FIG. 7,magazine 110 may be configured to hold a plurality of carton blanks 111in a vertically stacked, flattened configuration, and be operable tomove the stack of carton blanks 111 longitudinally in a directiongenerally parallel to longitudinal axis Y under the control of PLC 132,to a pick up position where an erector head 120 a and 120 b can retrievecartons from the magazine.

Magazine 110 may comprise a single conveyor or other blank feedapparatus to deliver blanks to a pick up location. In the illustratedembodiment of FIGS. 1A to 9, two conveyors are disclosed: an in-feedconveyor 204; and an alignment conveyor 206. However, as will describedhereinafter in other embodiments, the blank feed apparatus may beconfigured with multiple in-feed conveyors feeding cartons/cases frommultiple magazines that hold carton/case blanks having differentconfigurations. This enables a system 100 to by automation, selectivelyand sequentially erect cartons that differ in size, type, and/orconfiguration from each other.

Returning to system 100 of FIGS. 1A to 9, in-feed conveyor 204 may beconfigured and operable to move a stack of blanks 111 from a stack inputposition (where a stack may be loaded onto conveyor 204 such as by humanor robotic placement) to a position where the stack of blanks istransferred to horizontally and transversely aligned, alignment conveyor206. Alignment conveyor 206 may be positioned longitudinally downstreamin relation to in-feed conveyor 204 and be used to move the stack ofblanks to the pick up position. Magazine 110 may be loaded with, andinitially hold, a large number of carton blanks 111 in a vertical stack,with the stack resting on in-feed conveyor 204. A rear wall 212 mountedto a lower portion of a magazine frame generally designated 202, can beconfigured to retain the one or more stacks from falling backwards wheninitially loaded on conveyor 204. Rear wall 212 may have a generallyplanar, vertically and transversely oriented surface facing the stack ofblanks 111. Rear wall 212 and conveyor 204 may be of an appropriatelength to be able to store a satisfactory number of stacks of blanks inseries on conveyor 204. PLC 132 can control the operation of conveyor204 to move one stack at a time to the alignment conveyor 206.

In feed-conveyor may have one or more stacks of blanks arrangedlongitudinally on a conveyor belt 214 so that they can in turn be fedonto alignment conveyor 206. A sensor may be provided in the vicinity ofconveyor 204 to monitor the number of stacks waiting on conveyor 204 andthat sensor may be operable to send a warning signal to PLC 132 that canalert an operator that the magazine is low and needs to be replenished(e.g. because the stack on the alignment conveyor being processed byerector head 120 is the only one left). The sensor may be a part number42GRP-9000-QD made by Allen Bradley.

Of particular note, a plurality of stacks of blanks might be provided onconveyor 204. Each stack may be included with some kind of informationindicator that can be read by an information reader such as electronicor an optical reading device. For example, a bar code may be provided ona stack of blanks such as on the top or bottom blank of the stack. Thebar code may be read by a suitably positioned bar code reader. The barcode reader may be in communication with PLC 132. The bar code mayprovide information indicative of a characteristic of the blanks in thestack. For example, the bar code may identify the size and/or type ofblank in a particular stack. Other information indicators may be usedsuch as for example RFID tags/chips and RFID readers. The informationcan then be automatically provided by the information reader to PLC 132which can determine whether the current configuration of system 100 canhandle the processing the particular type/size of blanks without havingto make manual adjustments to any of the components. It is contemplatedthat within a certain range of types/sizes of blanks, system 100 may beable to handle the processing of different types/sizes of blanks withoutmanual adjustment of any components of system 100. The bar code/RFID tagmay provide the information about the dimensions of the blank asdiscussed above and then PLC 132 can determine adjustments, if any thatneed to be made to (a) the erector device operation; (b) the magazineand the tamping apparatuses in the magazine; (c) to provide a suitablepath for the movement of the movement sub-system to provide for suitablepick up of a blank from the magazine and suitable handling by theerector device and the folding and sealing apparatus; and (d) adjustmentof at least some of the components of the folding and sealing apparatusto be able to process a particular blank or a particular stack ofblanks. The result is that system 100 may be able to processautomatically, at least some different types/sizes/configurations ofblanks to form different cartons, without having to make manual operatoradjustments to any components of system 100.

Conveyor 204 may include a series of transversely and horizontallyoriented rollers 210 mounted to the lower portion of a magazine frame202 for free rotation. Rollers 210 may allow for generally horizontallongitudinal downstream movement of the stack towards conveyor 206. Aconveyor belt 214 may be provided that may be driven by a suitable motorsuch as a DC motor or a variable frequency drive motor 291 (see FIG. 1b). Motor 291 may be DC motor and may be controlled through a DC motordrive (all sold by Oriental under model AXH-5100-KC-30) by PLC 132.

Conveyor belt 214 may have an upper belt portion supported on therollers 210. Once PLC 132 is given an instruction (such as by a humanoperator through HMI module 133), upper belt portion of belt 214 maymove longitudinally downstream towards conveyor 206. In this way belt214 can move a stack of blanks 111 longitudinally downstream, with thestack of blanks at its outer transverse portions also being supported onthe rollers 210. PLC 132 can control motor 291 through the motor driveand thus conveyor 204 can be operated to move and transfer the stacktowards and for transfer to the alignment conveyor 206.

Stack alignment conveyor 206 may also include a series of transverselyoriented rollers 208 that are mounted for free rotating movement to alower portion of the magazine frame 202. A conveyor belt 216 may bedriven by a motor 292 that may be like motor 291 and with acorresponding motor drive. Motor 292 may also be controlled by PLC 132.Belt 216 may be provided with an upper belt portion supported on rollers208 and upon which the stack of blanks 111 may be supported. Conveyorbelt 214 may be operated to move the stack of blanks 111 furtherlongitudinally until the front face of the stack abuts with a generallyplanar, vertically and transversely oriented inward facing surface offront end wall 218.

Conveyor belt 214 of conveyor 204 and conveyor belt 216 of conveyor 206may be made from any suitable material such as for example Ropanyl.

A sensor 242, such as an electronic eye model 42KL-D1LB-F4 made by ALLENBRADLEY, may be located within the horizontal gap between belt 214 andbelt 216. Sensor 242 may be positioned and operable to detect thepresence of the front edge of a stack of blanks as the stack of blanksbegins to move over the gap between conveyor belt 214 and conveyor belt216. Upon detecting the front edge, sensor 242 may send a digital signalto PLC 132 (see FIG. 1b ) signalling that a stack has moved to aposition where conveyor 206 can start to move. PLC 132 can then causethe motor 292 for conveyor 206 to be activated such that the top portionof belt 216 starts to move the stack downstream. In this way, there canbe a “hand-off” of the stack of blanks from in-feed conveyor 204 toalignment conveyor 206.

Once the rear edge of the stack of blanks 111 has passed the sensor 242a signal may be sent to PLC 132 (see FIG. 1b ) which can then respond bysending a signal to shut down the motor 291 driving belt 214 of conveyor204. Conveyor 204 is then in a condition ready to be loaded with anotherstack of blanks 111. Meanwhile conveyor 216 can continue to operate asit moves the stack of blanks 111 to the pick up position.

The presence of a stack of blanks 111 at the pick up location may bedetected by a sensor 240 that may be the same type of sensor as sensor242. The sensor 240 may detect the presence of the front edge of a stackof blanks at the pick up position and may send a digital signal to PLC132 signalling that a stack is at the pick up position. At the pick upposition, the stack of blanks may be “squared up” and thereafter, onceproperly aligned, single carton blanks 111 may be retrieved in seriesfrom the stack of blanks 111 by the alternate engagement of the erectorheads 120 a, 120 b with the upper most blank in the stack.

The magazine 110 may be configured and operable to enable the stack ofblanks 111 to be properly positioned and oriented in a pick up positionfor proper engagement by one of the erector heads 120 a, 120 b. Duringmovement of the stack of blanks 111 longitudinally by conveyors 204 and206, the left hand side of the stack of blanks may be supported andguided by a left hand side wall 200. Side wall 200 may be mounted to alower portion of lower frame 202 and side wall 200 may be orientedgenerally vertically and may extend longitudinally for substantially thefull lengths of conveyors 204 and 206.

The right hand side of the magazine 110 adjacent conveyor 204 may beleft generally open; however to the right hand side of conveyor 206there may be a right hand side guide wall 201.

Possible mounting arrangements for side walls 200 and 201 areillustrated in further detail in FIGS. 6A-6D. In this regard, lowerframe portion 202 may include bottom support plates 251, 255, 259 and263 that are supported on the ground terrain/floor with these platesbeing spaced from each other and oriented in a generally transverse,parallel relationship to each other. Each of support plates 251, 255,259 and 263 has mounted to an upper surface thereof, one of the tracks253, 257, 261 and 265. Side wall 200 may be supported by connectorblocks 267 that fit onto and are capable of sliding laterally on and inrelation to tracks 253 and 261. Similarly side wall 201 may be supportedby connector blocks 269 that fit onto and are capable of slidinglaterally on and in relation to tracks 255 and 263.

A drive mechanism may be provided to drive each of side walls 200 and201 on their respective tracks. For side wall 200, a drive mechanismthat is in electronic communication with PLC 132 can be provided. By wayof example, a servo motor 258 with gear head may be provided and be inelectronic communication with PLC 132 through a servo drive (as per FIG.1b ). Examples that could be used are servo motor MPL-B1530U-VJ42AA madeby ALLEN BRADLEY, in combination with servo drive 2094-BC01-MP5-S alsomade by ALLEN BRADLEY and gear head AE050-010 FOR MPL-A1520 made byApex.

A lead screw rod 262 may be inter-connected to servo motor/gear head258. Lead screw rod 262 may pass through a nut such as a brass nut 264.Nut may be fixedly secured to a plate 293. Plate 293 may beinterconnected to spaced, generally vertically oriented bar members 294.Bar members 294 may be interconnected to support frame (not shown)forming part of side wall 200. By activating servo motor/gear head 258,the rotation of the servo may rotate the screw rod 262. As rod 262passes through nut 264, the nut is moved laterally either inwards oroutwards, thereby causing wall 200 to slide on tracks 252, 261 inwardsor outwards depending upon the direction of rotation of screw rod 262.An encoder may be provided within or in association with servo drivemotor 258 and the encoder may rotate in relation to the rotation of therespective drive shaft of the servo drive. The encoder may be incommunication with, and provide signals to the servo drive which canthen pass on the information to PLC 132. Thus, PLC 132 may be able todetermine the longitudinal position of the screw rod 262 in real timeand thus the transverse position of side wall 200 and can operate theservo drive 258 to adjust the position of the side wall 200. Theparticular type of encoder that may be used is known as an “absolute”encoder. Thus once the encoder is calibrated so that a position of thescrew rod 262 is “zeroed”, then even if power is lost to system 100, theencoder can maintain its zero position calibration. However, as sidewall 200 is not moved during processing of a blank 111, the mechanismfor adjusting the transverse position of side wall 200 may alternativelybe a simple hand crank mechanism instead of a servo drive motor incommunication with PLC 132. It should be noted that a proper positionfor left side wall 200 during the processing of a blank stack is thatshown in FIG. 7, with the wall 200 in abutment with the left side edgesof the blanks in each stack. The proper positioning of wall 200 willensure that the datum line W1 when the blanks are flattened is properlytransversely aligned to be picked up by erector heads 120 a, 120 b andmoved through folding and sealing apparatus 130, as describedhereinafter in detail to achieve proper folding and sealing of thecarton blank.

Similarly, for side wall 201, a drive mechanism 260 (that may be thesame types of components that used for side wall 200) that is also inelectronic communication with PLC 132 may be provided. By way ofexample, a servo motor with gear head designated 260 may be provided andalso be in electronic communication through a servo drive with PLC 132.A lead screw rod 266 may be inter-connected to servo motor/gear head 266(which may be like servo/gear head 268). Lead screw rod 266 may passthrough a nut such as a brass nut (not visible in Figures) like nut 264.The nut may be fixedly secured to a plate 295. Plate 295 may beinterconnected to spaced, generally vertically oriented bar members 296.Bar members 296 may be interconnected to side wall support framegenerally designated 271 (see FIG. 6c ) that forms part of side wall201. By activating servo motor/gear head 260, the rotation of the servomay rotate the screw rod 266. As rod 266 passes through the nut, the nutis moved laterally either inwards or outwards, thereby causing wall 201to slide on tracks 257, 265. An encoder may be provided within or inassociation with servo drive motor 260 and the encoder may rotate inrelation to the rotation of the respective drive shaft of the servomotor. The encoder may be in communication with a servo drive and thusprovide signals to PLC 132. Thus, PLC 132 may be able in real time todetermine the longitudinal position of the screw rod 266 and thus thetransverse position of side wall 201. Thus PLC 132 can operate the servomotor 260 to adjust the position of the side wall 201. An “absolute”encoder may also be used in this application.

During operation of system 100 in erecting a carton, side wall 200 mayremain stationary, but side wall 201 may be moved laterally as part ofthe blank stack alignment procedure to provide for generallylongitudinal alignment of the side edges of blanks 111 in the stack asthey are held between side walls 200 and 201.

A lateral tamping apparatus may be secured to side wall 201 and may beused to affect lateral alignment of the front and rear side edges of theblanks 111 in the stack (i.e. the front and rear edges of the blanks inthe stack are generally aligned with a vertical axis such as axis Z inFIG. 7). A lateral tamping apparatus generally designated 275 mayinclude a horizontally and longitudinally oriented support plate 270that may be attached at either end to vertical members of side wallsupport frame 271. Attached to an outer surface of plate 270 may be atrack 272. Secured to track 272 for sliding longitudinal movement alongtrack 272 may be a slider block 273. Attached to slider block 273 may bea pair of upstanding support plates which at their upper ends aresecured to a double acting, pneumatic actuator 276 such as the modelDFM-25-80-P-A-KF Part #170927 made by Festo. Actuator 276 may have oneor more piston arms (not visible in FIG. 6b or 6 c because they areshown retracted). Piston arms of actuator 276 may reciprocate betweenretracted and extended positions—back and forwards in a longitudinaldirection. With reference to FIG. 1b , a pneumatic actuator may besupplied with pressurized air communicated through electronic solenoidvalves for causing the piston arms to retract and extend. The solenoidvalves may be a model CPE14-M1Bh-5J-1/8 made by Festo and may becontrolled by PLC 132. Alternatively, a linear servo drivesystem—similar to one described in connection with the movement of sidewalls 200 and 201—may be provided for this actuator. Such a servo drivesystem could be controlled by PLC 132. PLC 132 could make adjustments tothe movement of both side walls 200 and 201 as well as this actuator forthe lateral tamping apparatus, such that magazine 110 could beautomatically adjusted to process a wide range of sizes of blanks.

It should be noted that during the operation of system 100 in erectingcartons, the slider block 273 will not move along track 272. Sliderblock 273, and the components attached directly or indirectly theretoincluding actuator 276, will not move longitudinally during operation.However the longitudinal position of slider block 273 can be adjustedduring the set-up of system 100 when processing particular sizes ofcarton blanks.

Attached to the end of the piston arms of actuator 276 may be atransverse plate 278 that may pass through a longitudinally extendingslot 279 through side wall 201. The distal end of plate 278 from pistonarms is attached to a vertical tamper plate 280 that is positionedtransversely inwards from the inner surface of side wall 201. Retractionof the piston arms of actuator 276 can cause plate 278 to engage therear side edges of the blanks 111 in the stack and as the front edges ofthose blanks are pushed up against the inner surface of the front wall218, the front and rear edges of the blanks can be laterally aligned.While a pneumatic actuator 276 is illustrated, other alignment devicescould be used. For example, a linear servo drive in communication withPLC 132 might be employed, that would perform the same function but itcould electronically position the vertical tamping plate 280, and theoperator may not have to adjust it manually during system set up.

By operation of PLC 132, suitable adjustment of right side wall 201 andtamper plate 280, the blanks 111 can be moved to precisely the knownpick up location and their orientation may be “squared-up” blanks 111 ina stack of blanks that is held against front wall 218, and may thusensure that the blanks 111 are in the proper location for being engagedby the erector heads 120 a, 120 b.

In particular, once the stack of blanks 111 have generally reached thepick up location, PLC 132 can send a signal to drive mechanism 260 tocause the drive mechanism 260 to cause side wall 201 to move laterallyinwards towards the side of stack of blanks 111. PLC 132 will cause thedrive mechanism 260 to move a sufficient distance to cause the edges ofthe blanks 111 to become in contact along their length with innersurface of longitudinally aligned inner surface of side wall 201.However, PLC 132 will not cause side wall 201 to be moved to such anextent that it creates a force on the stack of blanks such that causesthe blanks to buckle/be damaged if they are compressed to a significantextent between side walls 200 and 201. PLC 132 may be able to determinehow much to move side wall 201 towards side wall 200 by virtue of thecarton size dimensions that have been inputted into the PLC, includingdimension H (see FIG. 10A). The amount of slight compression can be finetuned such as by trial and error for different sized carton. It shouldbe noted that for many sized cartons, the manufacturers comply withindustry standard carton sizes.

Once the longitudinal alignment has been completed by side wall 201, PLC132 can cause actuator 276 to be activated to cause the vertical plate280 to engage the rear edges of the blanks 111 in the stack. PLC 132 maycause the drive mechanism 260 to move a sufficient distance to cause therear edges of the blanks 111 to come in contact along their length withinner surface of laterally aligned inner surface of plate 280. However,the amount of retraction of the piston arms will not cause side wallvertical plate 280 to be moved to such an extent that it creates a forceon the stack of blanks that would cause the blanks to buckle/be damagedif they are compressed too much between plate 280 and front wall 218.The appropriate manual positioning and securement (such as by tighteningscrews appropriately positioned through block 273, can secure actuator276 at an appropriate longitudinal position on rail 270.

Thus, by way of review: The tamping actuator 276 may ride on the sideguide wall 200. For a carton of a particular size/shape, the tampingactuator 276 can be adjusted manually in a fore-aft direction so thatwhen the actuator 276 is retracted, the vertical tamper bar 280 is inthe right position to push the blanks up against the front wall 218(without squeezing them).

The sliding assembly of components that includes actuator 276 may alsohave a pointer or indicator, and on the stationary part of the magazinethere may be a numeric scale to assist in rapidly manually adjusting theactuator to the correct position on rail 270 for a known case size.

In review the tamping sequence for ensuring the blanks are properlysquared up at the pick up location steps include the following:

1. The right-hand-side magazine side guide wall 201 under control of PLC132 expands wide enough to allow the stack of blanks to enter onalignment conveyor 206, even if the stack is misaligned and/or theblanks in the stack are not perfectly square with each other and inrelation to the X-Y axes.

2. The belt 216 advances the stack of blanks 111 towards the front stopdatum and may abut with front wall 218

3. The tamping actuator 276 is extended, and then the side guide wall201 may contract to make contact with the side of the case stack andpress the side wall 201 against the left hand side guide wall 200. Thisaligns the cases so the side edges of blanks are aligned with each otherand the longitudinal side wall of the walls 200 and 201.

4. The tamping actuator 276 may retract, and the tamping bar 280 pressesthe stack forward, thereby aligning the blanks in the stack so thattheir front and rear edges are vertically aligned with each other andwith the inner face of the bar 280 and the inside surface of front wall218.

5. The blanks are then properly positioned so that the erector heads canbegin picking up blanks from the stack.

Turning now to other components of system 100, to retrieve blanks fromthe magazine 110, at least a first engagement device may be provided toengage a panel of a blank 111 and thus be able to hold and move theblank. Where the blank is a tubular blank, system 100 may be providedwith a first engagement device for engaging one panel (e.g. Panel A) ofa blank and a second engagement device for engaging a second panel (e.g.Panel B) of the blank. 111. The first and second engagement devices maycomprise one or more suction cups providing a suction force onto a panelacting generally normal to the surface of the panel that is engaged, asdescribed further below. Other types of suitable engagement devicesmight be employed. The first and second engagement devices may berotatable relative to each other so that the first panel can be rotatedrelative to the second panel. The first and second engagement devicesmay be mounted to a single common erector head.

With reference to FIG. 7, system 100 may be provided with a movementsub-system that may be a pair of movement apparatuses each supportingand moving one of erector heads 120 a, 120 b. Each erector head 120 a,120 b may have a dedicated, independently driven and controlled movementapparatus 115 a, 115 b. Thus erector head 120 a may be supported andmoved by movement apparatus 115 a. Similarly erector head 120 b may besupported and moved by movement apparatus 115 b. Movement apparatus 115a may be constructed in a manner that is substantially identical tomovement apparatus 115 b but may be configured as mirror image ofmovement apparatus 115 b. In this way, movement apparatus 115 a maysupport erector head 120 a from a right hand side and movement apparatus115 b may support erector head 120 b from a left hand side, in such amanner that the erector heads 120 a, 120 b may both be moved along thesame longitudinal and vertical path. The common path of erector heads120 a, 120 b, may be a cyclical path that lies substantially in or isparallel to a plane that it parallel both vertical axis Z andlongitudinal axis Y in FIG. 7. Thus movement of the erector heads 120 a,120 b may only be in vertical Z and longitudinal Y directions (i.e.directions parallel to axes Z and Y in FIG. 7), and there may be nosubstantial movement in a lateral Z direction (i.e. a direction parallelto axis X in FIG. 7). If the movement of the erector heads 120 a, 120 bis restricted to only Z and Y directions, a moving apparatus for eachcan be constructed that is relatively less complex than if movement inall three directions is required.

The movement of heads 120 a, 120 b by movement apparatuses 115 a, 115 brespectively, may be synchronized such that they may travel along thesame longitudinal and vertical path but they move out of phase with eachother so that one erector head does not interfere with the other erectorhead, as will be described further below. Thus, the relative positionsof the two erector heads 120 a, 120 b can be arranged so that the headsthey do not collide or otherwise interfere with each other duringoperation of system 100.

Only the detailed construction of left side movement apparatus 115 bwill be described herein, it being understood that movement apparatus115 a may be constructed in a substantially identical manner as a mirrorimage of moving apparatus 115 b. With particular reference to FIGS. 4,5, 7, 8, 9 and 17, movement apparatus 115 b may include a verticalmovement device and a horizontal movement device. The vertical movementdevice may include a generally hollow vertically oriented support tube169 that may be generally rectangular in cross section. Support tube 169may be formed from a unitary tubular piece of material or may be formedinto opposed, vertically extending and oriented, surfaces 164, 165, 166and 168 that may be inter-connected together using conventionalmechanisms such as bolts, welding etc. Support tube 169 may be securedto a horizontally extending brace plate 182. Brace plate 182 may beinterconnected to a vertically extending brace plate 180. The bottomportion of brace plate 180 may be interconnected by way of a series ofangled plates generally referred to as 183, to the lower end of supporttube 169.

At the upper end of support tube 169 may be mounted a freely rotatablepulley wheel 155 b. At the bottom end of plates 164, 166, erector head120 b may be fixedly attached to support tube 169 by means of ahorizontally extending mounting plate that is connected to support tube169, which engages with a pair of spaced mounting block 190 a, 190 bthat may be joined with bolts through bolt holes 191 a, 191 b in blocks190 a, 190 b that also pass through the mounting plate at the bottom ofsupport tube 169. Thus, as erector head 120 b is interconnected tosupport tube 169, erector head 120 b will move in space with supporttube 169.

To support the support tube 169 and erector head 120 b that is connectedthereto, and facilitate movement of the support tube 169 and erectorhead 120 b in horizontal motion, a horizontal movement device may beprovided and may include a slide block 158 that may use a rail system tomove horizontally and may be provided with a pair of spaced,longitudinally and horizontally extending short inner blocks, each onefitting on one longitudinally extending rail 160, 162 that holds theblocks securely but allows blocks to slide horizontally relative to therails. An example of a suitable rails system is the Bosch Rexroth ballrail system in which the rails are made from steel and the blocks have arace of ceramic balls inside allowing the block to slide on the rails.Rails 160, 162 are generally oriented horizontally and may be attachedto the frame 109. Slide block 158 may be mounted to rails 160 or 162 forhorizontal sliding movement along the rails. Secured to the front faceof slider block 158 are four freely rotatable pulley wheels 155 a, 155c, 155 d and 155 f which have drive belt 153 pass around them asdescribed below. Slide block 158 may also use a rail system to allowsupport tube 169 to be connected to it and also move vertically relativeto slide block 158. Accordingly, extending vertically along a backsurface of tube 169 may be a vertically and longitudinally extendingrail. Support block may have a runner block interconnected to thevertical rail on support tube 169. Thus support tube 169 can slidehorizontally relative to slide block 169. Again, a suitable rail systemis the Bosch Rexroth ball rail system referenced above.

A drive apparatus may also be provided to drive the horizontal movementdevice and the vertical movement device. For example, the driveapparatus may include a pair of drive motors interconnected to a drivebelt, with the drive belt being inter-connected to the horizontal andvertical movement devices. For example, the drive apparatus may includea left belt drive motor 150 (which may be a servo motor such as themodel MPL-B330P-MJ24AA made by Allen Bradley) may be mounted to alongitudinally extending beam member 108 that is connected to frame 109(see FIGS. 1a , 2 and 3). Servo drive 150 may have a drive wheel 152.Similarly, a right belt drive 154 (which may be a servo motor like servodrive 150) may also be mounted to beam member 108 connected to frame109. Servo drive 154 may have a drive wheel 156. Servo motor 152 may belongitudinally spaced from, and may be horizontally aligned with, servomotor 154. Both servo motors 150 and 154 can be driven in bothdirections at varying speeds, such rotation being controllable throughservo drives by PLC 132 (see FIG. 1b ). Both servo motors 150 and 154may be provided with two separate ports 364 a, 364 b. One for the portsmay be for supplying a power line and the other for a communication lineto facilitate the communication with the servo drive and PLC 132. Itshould be noted that all of the servo motors described in this documentmay be similarly equipped. Servo motors 150, 154 may also have a thirdinput which may provide input for an electric braking mechanism.

Apparatus 115 a may also include a continuous drive belt 153 that mayfor example be made from urethane with steel wires running through itBelt 153 may be engaged and may be driven by motors 150 and 154 undercontrol of PLC 132 as it may independently control through theirrespective servo drives, the operation of both servo motor 152 and servomotor 154. Belt 153 extends continuously from a start location at thebottom left side of support tube 169, where belt is fixedly attached toa belt block 159 a that is attached to support tube 169. From there beltextends upwardly on a first portion 153 g to block pulley 155 f, aroundthe upper side of block pulley 155 f. From block pulley 155 f, belt 153extends horizontally along a second portion 153 h to servo drive wheel152. The belt then passes around and is engaged by servo drive wheel152, on a third portion 153 a on the underside of pulley 155 a, upwardsalong a fourth portion 153 b to pulley 155 b. From there belt extendsaround pulley 155 b, downwards on a fifth portion 153 c to block pulley155 c, around block pulley 155 c along a sixth portion 153 d to servodrive wheel 156. After passing around and being engaged by servo drivewheel 156, belt 153 extends continuously from around servo drive wheel156, on to a seventh portion 153 e to the upper side of block pulley 155d. From block pulley 155 d, belt 153 then extends vertically downwardsalong an eighth portion 153 f to belt block 159 b where the beltterminates. Belt 153 vertically supports the support tube 169 both atthe bottom as it is interconnected to support tube 169 with blocks 159a, 159 b, and at the top of support tube 169 where it passes 155 b. Thusbelt 153 is indirectly also vertically supporting erector head 120 b.Furthermore, by adjusting the relative rotations of servo drive wheels152 and 156, the relative lengths of all belt portions can be adjustedthrough the operation of the servo motors 150 and 154. Thus, therelative vertical position of support tube 169 relative to slide block158 can be adjusted. Additionally, by adjusting the relative rotationsof servo drive wheels 152 and 156, through the operation of the servomotors 150 and 154 the horizontal position of slide block 158 on rails160, 162 can be adjusted thus altering the horizontal position ofsupport tube 169 and erector head 120 b. It will thus be appreciatedthat by adjusting the direction and speeds of rotation of drive wheels152, 156 relative to each other the support tube 169 can be movedvertically and/or horizontally in space within the physical constraintsimposed by among other things the position of the servo drive wheels 152and 156, the length of the belt 153, and the length of support tube 169.The following will be appreciated with reference to FIG. 17 inparticular:

-   -   If wheels 152 and 156 both remain stationary then the position        of support tube 169 will not be altered;    -   If wheels 152 and 156 both rotate in the same clockwise        direction and at the same speed relative to each other, then        support tube 169 (and thus erector head 120 b) will move        horizontally from right to left;    -   If wheels 152 and 156 both rotate in the same counter-clockwise        direction and at the same speed relative to each other, then        support tube 169 (and thus erector head 120 b) will move        horizontally from left to right;    -   If wheel 152 rotates counter-clockwise, and wheel 156 rotates in        opposite clockwise rotational directions, but both wheels rotate        at the same rotational speed relative to each other, then        support tube 169 (and thus erector head 120 b) will move        straight vertically downward;    -   If wheel 152 rotates clockwise, and wheel 156 rotates in        opposite counter-clockwise rotational directions, but both        wheels rotate at the same rotational speed relative to each        other, then plates 164, 166 will move straight vertically        upwards.

It will be appreciated that if the speeds and directions of the twoservo motors are varied in different manner, then the motion of thesupport tube 169 (and thus erector head 120 b) can be created that hasboth vertical upwards or downwards component as well as a horizontallyright to left, or left to right movement. Thus any desired path withinthese two degrees of freedom (vertical and horizontal) can be createdfor support tube 169 (such as a path having curved path portions) (andthus erector head 120 b). Thus by controlling the rotational directionand speed of the motors 150, 154 independently of each other, PLC 132can cause support tube 169 (and thus erector head 120 b) to move alongany path, within the physical constraints imposed by the spacing of thedrive wheels 152, 156 and pulley wheel 155 b, and the bottom of supporttube 169 in vertical and horizontal directions to allow for the enderector 120 b to carry a carton blank 111 through the various processingsteps performed by system 100.

It will also be appreciated that by providing two opposed movingapparatuses 115 a, 115 b, the movements of each of the end effectors 120can be co-ordinated and synchronized so that even though they move alongthe same path, the movement of the end effectors are out of phase (forexample by 180 degrees).

Thus the movements of one end effector will not interfere with themovement of the other. An encoder may be provided for each of the servodrive motors 150 and 154 and the encoders may rotate in relation to therotation of the respective drive wheels 152, 156. The encoders may be incommunication with, and provide signals through the servo drives to PLC132. Thus PLC 132 can in real time know/determine/monitor the positionof the belt 153 in space and thus will determine and know the positionof the erector head 120 b in space at any given time. The particulartypes of encoders that may be used are known as “absolute” encoders.Thus the system can be zeroed such that due to the calibration of bothencoders of both servo drives 150 and 154, the zero-zero position of theerector head in both Z and Y directions is set within PLC 132. Thezero-zero position can be set with the erector head at its mosthorizontally left and vertically raised position. PLC 132 can thensubstantially in real time, keep track of the position of the erectorhead 120 b as it moves through the processing sequence for a blank 111.

PLC 132 and the encoders associated with the servo motors 150, 154 andtheir servo drives on each of apparatuses 115 a, 115 b may be capable ofbeing able to be set at zero-zero positions for each of the two separateerector heads 120 a, 120 b. PLC 132 can then substantially in real time,keep track of the position of both the erector heads 120 a, 120 b asthey both independently move through the processing sequence for a blank111.

Also associated with moving apparatus 115 b is a first, generallyhorizontally oriented caterpillar device 114 having an input end 114 aand an output end 114 b. A second, generally vertically orientedcaterpillar device 118 is also provided and has an input end 118 a, andan output end 118 b. Caterpillars 114 and 118 may have a hollow cavityextending along their length. Within the cavities of caterpillars 114,118 hoses/wires carrying pressurized air/vacuum andelectrical/communication wires can be housed. Caterpillar 114 allowssuch hoses and wires to move longitudinally as the support tube 169 anderector head 120 b are moved longitudinally. Caterpillar 118 allows suchhoses and wires to move vertically as the support tube 169 and erectorhead 120 b are moved vertically. The hoses and wires may extend fromexternal sources to enter at an inlet 114 a of caterpillar 114 andemerge at an outlet 114 b. Once leaving outlet 114 b, the hoses andwires may extend to enter at an inlet 118 a of caterpillar 118 andemerge at an outlet 118 b. These hoses and wires may then pass fromoutlet 118 b into the input hoses 190 and 191 on erector head 120 b (seeFIG. 30). In this way both pressurized air/vacuum and/or electricalcommunication wires may be brought form locations external to the frame109 onto the moving erector head 120 b. An example of suitablecaterpillar devices that could be employed is the E-Chain Cable CarrierSystem model #240-03-055-0 made by Ignus Inc. It should be noted thatelectrical communication between the PLC 132 and the erector head 120 bcould in other embodiments be accomplished using wireless technologiesthat are commercially available.

Turning now to FIGS. 30 to 33, left hand side erector head 120 b isshown in isolation. Right hand side erector head 120 a may beconstructed in the same manner as erector head 120 b, but may besupported from the right hand side moving apparatus 115 a, in contrastto erector head 120 b which may be supported from the left hand side byleft hand moving apparatus 115 b.

Erector head 120 b may have a body generally designated as 300 that maycomprise of a number of components. Many of the components of erectorhead 120 b may be made from a strong material such as a metal (e.g.aluminium, steel, etc.), a hard and strong plastic such as or othersuitable materials including composite materials.

Erector head 120 b may be generally configured to handle a range ofsizes of carton blanks 111 that can be formed into a carton. Erectorhead may be configured by providing easy attachment to support tube 169using mounting blocks 190 a, 190 b and bolts etc. to permit for the easyinterchange of erector heads 120 so that the system can in somecircumstances, be readily adapted to forming differently sized/shapedcartons from differently configured blanks.

In one embodiment, erector head 120 b may include a rotatable paddle 310connected to a distal end portion 314 a of a paddle arm 314. Paddle arm314 may have an end portion 314 b opposite to distal end portion 314 a,that is formed with a circular opening that facilitates arm 314 beingconnected to a shaft 316. Paddle 310 can rotate with shaft 316 about thelongitudinal axis of shaft 316. Shaft 316 may be connected to a rotaryactuator 399 such as a double acting rotary pneumatic actuatormanufactured by Festo under engineering part # DSM-32-270-CC-FW-A-B.Actuator 399 can cause rotation of shaft 316 clockwise andcounter-clockwise around its axis of up to 270 degrees. Rotary actuator399 may be supplied with pressurized air supplied by hoses (not shown)connected to ports 395 and 397. Those hoses may also be connected to asolenoid valve device 340 which may be controlled by PLC 132. In thisway the rotation clockwise and counter-clockwise of paddle 310 may becontrolled by PLC 132.

Also formed as part of body 300 of erector head 120 b is a bottomsuction plate 327 that is generally shaped in a square crossconfiguration to provide flanged openings for such cups. In each of theopen flanges of plate 327 is positioned a suction cup 312. It should benoted that while many types of suction cups may be employed on theerector head, a preferred type of suction cup is the model B40.10.04ABmade by Piab. Two of the suction cups 312 are mounted to a generallylongitudinally oriented support block 319 a and the other two suctioncups are mounted to a second generally longitudinally oriented supportblock 319 b.

Support blocks 319 a and 319 b are generally oriented longitudinally inspace apart, parallel relation to each other and each block 319 a, 319 bis joined to other body components of body 300. Blocks 319 a, 319 b eachhave open passageways that interconnect each suction cup 312 with anoutlet from a vacuum generator 330. Vacuum generator 330 may be anysuitable vacuum generator device such as for example the modelVCH12-016C made by Pisco. Vacuum generators 330 each have an inletinterconnected to a hose (not shown) that can carry pressurized air tothe vacuum generator. The vacuum generator converts the pressurized airsupplied to the inlet port, into a vacuum at one of the outlet ports.That vacuum outlet port is interconnected through the passageway inblocks 319 a, 319 b to a suction cup 312 so that the suction cup canhave a vacuum force. Interposed along the pressurized air channelrunning between each vacuum generator 330 and the source of pressurizedair that may be an air compressor (see FIG. 1b ), may be located asolenoid valve device 340 that may for example be a modelCPE14-M1BH-5L-1/8 made by Festo. Valve device 340 may be in electroniccommunication with PLC 132 and be controlled by PLC 132. In this way PLC132 can turn on and off the supply of vacuum force to each of thesuction cups 312. To channel the compressed air appropriately, valves invalve device 340 can be driven between open and closed positions bysolenoids responsive to signals from PLC 132. Electrical lines carryingsignals to and from PLC 132 could also pass through hose 190 to operatethe valve device 340.

Still with reference to FIGS. 30 to 33, downward extending end portions323 of longitudinal support block 319 have openings 331 that areconfigured to receive a transversely mounted shaft 342. Shaft 342 may bemounted for rotation within openings 331. At one end of shaft 342 may bemounted a gear wheel device 360 that is configured to rotate with shaft342. Gear wheel 360 may be interconnected to a drive wheel of a gear box362 to form a mitre gear connection. Gear box 362 may be driven by aservo motor 364 mounted above gear box 362. Servo motor 364 may also bea model MPL-B1530U-VJ44AA made by ALLEN BRADLEY and gear box may be amodel AER050-030 FOR MPL-A1520 AB SERVO MOTOR made by Apex.

In FIG. 30, servo motor 364 is shown with two separate ports 364 a, 364b. One for the ports may be for supplying a power line and the other fora communication line to facilitate the communication with the servodrive and PLC 132. It should be noted that all of the servo motorsdescribed in this document may be similarly equipped. Servo motor 364may, through connection with a servo drive (see FIG. 1b ), be controlledby and be in communication with PLC 132. An encoder may be providedwithin or in association with servo motor 364 and the encoder may rotatein relation to the rotation of the respective drive shaft of the servomotor. The encoder may be in communication with, and provide signals tothe servo drive and thus to PLC 132. PLC 132 may be able to determinethe rotational position of the shaft 342. Thus, when appropriate signalsare provided from PLC 132, so servo motor 364 can be operated and cancause shaft 342 to rotate in a particular desired direction at aparticular desired rotational speed for a desired amount of time. ThusPLC 132 can control the rotational position of shaft 342.

Mounted to shaft 342 between end portions 323 of support blocks 319 a,319 b is a rotator device generally designated 350. Rotator device 350is fixedly attached to shaft 342 and will rotate with shaft 342. Rotatordevice 350 includes an arm 351 having one end fixedly mounted to shaft342. The opposite end of arm 351 has a mounting block 353 attached toit.

Secured to mounting block 353 may be a pneumatic actuator 325 that mayfor example be a model DFM-12-80-P-A-KF, or part #170905 made by Festo.Actuator 325 may be supplied with pressurized air to activate the devicethat may be controlled by solenoid valve device 340 in the supply line.The solenoid valve 340 may be in communication with and be controlled byPLC 132 (see FIG. 1b ). Actuator 325 may be actuated to reciprocatepiston arms 326 between an extended position and a retracted position.PLC 132 may send a signal to valve device 340 to operate actuator 325 toextend piston arms 326 at a particular angular position of arm 351and/or location of erector head 120 b that is provided by the encoderassociated with servo motor 364. Similarly, PLC 132 may send a signal tovalve device 340 to activate arms 326 to be retracted at a particularshaft 342 angular position, and to retract piston arms 326 at aparticular angular position, of arm 351 and/or a particular location oferector head 120 b. PLC 342 may cause, acting through valve device 340,actuator 325 to be actuated at approximately the same time as the cups320 have contacted the surface of downward facing panel D and/or whenrotation of arm 351 is just about to begin or has just commenced. Pistonarms 326 may be completely extended by the time arm 351 has rotatedabout 45 degrees.

Mounted to distal ends of piston arms 326 is a mounting block 328 whichmay be configured to support a pair of suction cups 320. Blocks 328 mayhave open passageways (not shown) that interconnect each suction cup 320with an outlet from another vacuum generator 330. Vacuum generator 330may be any suitable vacuum generator device such as for example themodel VCH12-016C made by Pisco. As indicated above, vacuum generators330 each have an inlet interconnected to a hose (not shown) that cancarry pressurized air to the vacuum generator. Vacuum generators 330convert the supplied pressurized air supplied the inlet port to a vacuumat one of the outlet ports. That vacuum port is interconnected throughthe passageway in block 328 to a suction cup 320 so that the suction cupcan have a vacuum force. Interposed along the pressurized air channelrunning between each vacuum generator 330 associated with suction cups320 and the source of pressurized air may be located the same valvedevice 340. Valve device 340 may be interconnected electronically(either with a wireless system or wired communication connection) to PLC132 and be controlled by PLC 132. In this way PLC 132 can also turn onand off the supply of vacuum force to each of the suction cups 320.

With reference also to FIG. 11, suction cups 312 can be employed toengage and hold onto the top panel A of blank 111. Once a blank 111 isretrieved from the top of the stack of blanks, the rotator arm 351 canbe rotated approximately 180 degrees such that suction cups 320 ofrotator device 350 can engage and hold onto the underside panel D ofblank 111. Once suction cups 320 have engaged panel D the arm 351 can berotated 90 degrees backwards in the opposite rotational direction andthe opposing vacuum forces created by suction cups 312 above and suctioncups 320 below, cause the tubular blank 111 to be moved from a flattenedconfiguration to an open configuration as panel D is rotatedsubstantially 90 degrees relative to panel A. The air suction force thatmay be developed at the outer surfaces of suction cups 320 and 312 willbe sufficient so that when activated they can engage and hold top panelA in a stationary position relative to erector head 120 b and rotatepanel D relative to panel A to open up the tubular blank to a generallyrectangular configuration. The vacuum generated at suctions cups 320 and312 can also be de-activated by PLC 132 at appropriate times by sendingsignals to valve device 340.

Each erector head 120 a, 120 b may be configured to be able to handle awider range of different sized/dimensioned blanks 111 by providing foradditional suction cups 320 and 312 positioned at different locations onthe erector heads. Suction cups 320, 312 could each be “self-sealing” of“self-plugging” suction cups which if not engaging and sealing with asurface of a particular blank that is being processed, may automaticallybecome blocked. This would allow the vacuum/suction forces to bemaintained on other suctions cups that may have the source ofpressurized air/vacuum interconnected thereto and which are engaging apanel of a blank 111. In this way, each erector head may be adapted tohandle a wider variety of sized/dimensioned blanks and cartons/casesthat can be formed therefrom.

The opening of the blank 111 may be assisted by the extension of pistonarms 326 of actuator device 325 during rotation of the rotator arm 351.Preferably when rotator arm 351 has rotated somewhere in the range ofabout 30-60 degrees back to the 90 degree position, and preferably whenit is at approximately 40-50 degrees, and most preferably when it is atabout 45 degrees, then the piston arms 326 may be fully extended. Thisextension of arms 326 and thus of suction cups 320 in a generallytangential direction relative to the rotation of arm 351 compensates forthe offset of the axis of rotation of the arm 351 compared to the axisof rotation of the blank that extends along the fold line between panelsA and D. The effect of the extension of piston arms 326 once the arm isrotated such as to 90 degrees ensures that the panel D is also orientedat 90 degrees to panel A.

Once a blank 111 has been opened to the configuration shown in FIG. 11,then PLC 132 can send a signal to valve device 340 which causes rotaryactuator 399 to rotate shaft 316 and thus rotate paddle 310. Paddle 310can then engage trailing flap K of blank 111 and cause it to fold aboutits fold line where it joins to panel D. Thus flap K can be foldedinwards towards the bottom opening of blank 111. Leading bottom flap Jmay also be folded about its fold line which joins it with panel B byengagement of the flap with upper and lower folding rails/ploughs 700,701 that form part of folding and sealing apparatus 130. As the blank111 held by erector head 120 b is moved longitudinally downstream intothe folding and sealing apparatus 130 the leading bottom flap J can befolded inwards so that both bottom flaps K and J are folded inwards tostart the formation of the bottom of the carton.

Another feature of erector head 120 b that can be noted is that a cartonlocation sensor apparatus may be provided and may include areciprocating sensor rod 380 which, when not in contact with a blank,extends downwards through an aperture 381 in plate 327, below the levelof the plane of suction cups 312. When the erector head 120 b is broughtvertically downwards to retrieve a blank on a stack of blanks 111 inmagazine 110, the erector head's movement just prior to suction cups 312contacting with the upper surface of the blank will be generallyvertically downwards. Prior to the suction cups 312 contacting thesurface of a panel A of a blank, sensor rod 380 will engage the surfaceof panel A and cause sensor rod 380 (which may be resiliently displaceddue to a spring mechanism biasing the rod downwards) to be pushedupwards. This movement upwards of sensor rod 380 relative to plate 327will physically cause a sensor (not shown) to be activated and send asignal to PLC 132. The sensor may be an inductive proximity sensor. Themetal cylinder fixed on the rod is sensed by the sensor's circuitrybecause it changes the inductance of the induction loop inside thesensor. The sensor may be 871FM-D8NP25-P3 made by ALLEN BRADLEY. PLC 132may respond to that signal by causing servo drives 150 and 154 to slowdown so that the final few centimeters (e.g. 3.5 cm) of movementdownwards towards contact between cups 312 and the upper surface ofpanel A occurs at a much slower rate and also PLC knows how much furthervertically downwards erector head 120 b must be lowered to establishproper contact between suction cups 312 and panel A. It should also bethat sensor rod 380 and associated sensor device can also be used toensure that PLC 132 is aware of whether once a blank has been engaged inthe magazine 110, it stays engaged with erector head 120 until theappropriate release location is reached, such as once erection of thecarton has been completed.

The particular arrangement of suction cups and rotating paddle onerector heads 120 can be designed based upon the configuration of thecarton blank and the particular panels and flaps that need to berotated. It will also be appreciated that on erector head 120 that isillustrated, suction cups are used to apply a force to hold and/orrotate panels of a carton blank. However alternative engagementmechanisms to suction cups 312 and 320 could be employed.

With particular reference to Figures including FIGS. 1 to 15 and 17,system 100 may also include a folding and sealing apparatus 130. Railand plough apparatus may be configured to cause all remaining flaps of ablank 111 to be appropriately folded and sealed to produce a cartonconfiguration that is suitable for delivery to a discharge conveyor suchas discharge conveyor 117. Apparatus 130 may include the followingcomponents: upper and lower folding rails/ploughs 700 and 701; a cartonsupport plate 703; a discharge chute 750; an upper flap closing device705; a lower flap closing device 707; a right hand compression device706; and a left hand compression device 704; and a glue applicator 709(see FIG. 1) having one or more nozzles positioned to apply adhesive toflaps such as flaps J and K. Each of the rails and actuator devices ofapparatus 130 may be supported by rods or other members to interconnectthe components to support frame 109.

Upper flap actuation device 705 may include a pneumatic actuator device704 a having its piston arms connected to an upper plough 708 a.Similarly, lower flap actuation device 707 may include a pneumaticactuator device 704 b having its piston arms connected to an upperplough 708 b. Actuator devices 704 a, 704 b may be the modelDFM-25-100-P-A-KF, part #170928 made by Festo.

Right hand compression device 706 may include a central pneumaticactuator 710 with telescoping extendible support rods 712 and 714horizontally aligned and disposed on either side of actuator 710.Actuator 710 may be a model DNC-32-100-PPV-A part #163309 made by Festo.With particular reference to FIG. 26, actuator 710 may have piston armsthat along with ends of support rods 712 and 714 connected to alongitudinally extending sealing plate 716 having attached theretolongitudinally extending upper rail 717 a, and lower rail 717 b. Upperrail 717 a is positioned to be able to engage upper major flap F andlower rail 717 b is positioned to engage lower major flap G when pistonarms of actuator device 710 are extended horizontally and transverselyinwards to push flaps F and G into engagement with flaps K and J thatare positioned underneath.

Left hand compression ram device 704 has an actuator arm 711 which maybe actuated by an actuator device 719 with a vertically andlongitudinally disposed plate 720 attached to the end of the actuatorarm. Actuator device 719 may be a double acting pneumatic actuator (notshown) that may be provided with pressurized air through hoses, with theair flow being controlled by the solenoid valve device that may becontrolled by PLC 132. Other embodiments are possible. For example, withreference to FIG. 26A, a servo-driven actuator for arm 711 may beprovided that includes a mounting block 741 that can travel along a railguide 745 that is secured to a horizontal and longitudinally extendingplate forming part of a support frame 746. Mounting block 741 can slidehorizontally along rail 745. An L-shaped plate 743 interconnects arm 711to sliding block 741. Sliding block 741 may also be connected such aswith nuts and bolts on its underside to a drive belt 757 made of anysuitable material such as for example the same material that may be usedin the belts for the moving apparatuses 115—namely a urethane timingbelt with steel wires running through it. Continuous drive belt 757 mayextend between a freely rotating pulley 759 mounted to an end of frame746, and a drive wheel of a servo motor 761. Through a servo drive andan absolute encoder. Servo motor 761 may be an Allen Bradley model ABMPL-B320P-MJ22AA and may be interconnected with servo drive to PLC 132.The servo drive may be Allen Bradley model AB. 2094-BM01-S. Motor 761may be coupled to drive wheel for the belt thorough an APEX GEARBOXmodel AE070-005.

PLC 132 may control the rotation of the drive wheel driven by the servomotor 761 through use of an encoder (that may be an absolute encoder).Thus the movement of belt 757 can be controlled and PLC can determine inreal time, the position of ram arm 711 and thus of compression plate720. Depending upon the type of, and thickness of material from whichblank 111 is formed, the positioning of plate 720 relative to the plateof right hand compression device 706 can be adjusted by PLC 132 toensure an appropriate degree of compression of the flaps of blank 111positioned there between.

Each of actuator devices 704 a, 704 b, 710 may be double actingcylinders and they may be supplied with pressurized air that iscontrolled through an electronic valve device (not shown). The valvedevice may a model CPE14-M1Bh-5J-1/8 valve unit that may be incommunication with and be controlled by PLC 132. In this way, PLC 132can cause the piston arms to be extended and retracted during theprocessing of carton blanks to achieve the closure and sealing of theflaps.

Actuator device 704 a and its plough 708 a may be appropriatelypositioned and angled downwards (such as at about 45 degrees to thevertical) to be able to fold down major flap F sufficiently to be ableto be engaged by right hand compression device 706. Similarly, actuatordevices 704 b and its plough 708 b may be appropriately positioned andangled upwards (such as at about 45 degrees to the vertical) to be ableto fold up major flap G sufficiently to be able to be engaged by righthand compression device 706, substantially simultaneously, or at leastallowing of right hand compression device 706 to be able to compressboth flaps F and G at the same time towards minor flaps J and K thathave upper surfaces containing some adhesive.

Applicator 709 can have nozzles appropriately positioned and theiroperation may be controlled by PLC 132. Applicator 709 can apply asuitable adhesive to flaps such as leading minor flap J and trailingminor flap K, once they have been folded inwards to form part of thecarton bottom. An example of a suitable applicator 709 that can beemployed is the model ProBlue 10 applicator made by Nordson Inc. Anexample of a suitable adhesive that could be employed with on a cartonblank 111 made of cardboard is Cool-Lok 034250A-790 adhesive availablefrom Lanco Adhesives, Inc. Applicator 709 may be in electroniccommunication with PLC 132 which can signal the applicator to applyadhesive at an appropriate time during the positioning of the erectorheads 120 a, 120 b

Left hand compression device 704 may be used to enter the carton fromthe left side and compress flaps F, G, J and K between ram plate 720 ofleft hand compression device 704 and the rails 717 a, 717 b of righthand compression device 706. This compression assists in ensuring thatthe panels are compressed together to ensure that the adhesiveappropriately bonds the flaps together to make a solid carton bottom.

In some embodiments, once the left hand compression device 704 and righthand compression device 706 have completed the compression of the flaps,PLC 132 can send a signal to solenoid valve devices causing thecompression devices to be withdrawn. The carton will then have beenfully erected and is suitable to be loaded with one or more items.Erector head 120 b may then carry the erected carton to a dischargechute 750 and then release it such that it falls onto discharge conveyor117 which can then move the erected carton away for further processing.In other embodiments such as the one illustrated, the erected carton 111can be released and fall onto support plate 703 and remain there untilthe next carton blank carried by another erector head moved by anothermovement apparatus (such as erector head 120 a moved by movementapparatus 115 a) moves the next carton blank into the location where itwill be folded, sealed and compressed. In doing so the newly arrivedcarton blank pushes the previous fully erected carton downstream whereit may fall onto discharge conveyor 117. Carton discharge conveyors arewell known in the art and any suitable known carton conveyor may beutilized.

Other examples of transfer devices that might be employed to transferthe carton from apparatus 130 to a carton discharge conveyor include a“blow-off” system that may use one or more jets of compressed air, asuction cup system, the use of pushing arm or simply allowing forfreefall of the formed carton.

A sensor 243 (see FIG. 2) such as an electronic eye model 42KL-P2LB-F4made by ALLEN BRADLEY may be located near the bottom of discharge chute750. Sensor 243 may be positioned and operable to detect the presence orabsence of an erected carton at the input to the discharge conveyor 117.In this way, PLC 132 can be digitally signalled if an erected cartonblank 111 is in place at the bottom of the chute 750 such that anothererected carton can not be discharged down the chute 750. If so, thesystem 100 can be stopped by PLC 132 until any fault at dischargeconveyor 117 can be rectified.

The overall operation of system 100 will now be described further.

As an initial step PLC 132 may be accessed by an operator through HMI133 to activate system 100. The system 100 may be initialized with PLC132 ensuring that all components are put in their “start” positions. Atsubstantially the same time, a stack of cartons may be placed at theinput end of conveyor 204 and system 100 may then be activated (such asby PLC 132 being instructed through HMI 133 to commence the processingof a stack of blanks 111.

PLC 132 may then send an instruction to the drive motor of inputconveyor 204 to commence to drive belt 214 causing stack of blanks 111to move downstream. Sometime prior to the stack of blanks reachingalignment conveyor 206, the right-hand-side magazine side guide wall 201under control of PLC 132 will be driven by servo motor 260 to expandwide enough to allow the stack of blanks to enter on alignment conveyor206, even if the stack is misaligned and/or the blanks in the stack arenot perfectly square with each other. The stack of blanks is moveddownstream, until once the front edge of the stack of blanks passes thedownstream edge of conveyor 204, sensor 242 will send a signal to PLC132 indicating that the front edge of the stack has reached the input toalignment conveyor 206. In response, PLC 132 may then send aninstruction to the drive motor of input conveyor 204 to commence todrive belt 216 causing stack of blanks 111 to move downstream towardsend wall 218 of magazine 110. Once the front edge of the stack of blanks111 reaches end wall 218, sensor 240 will send a signal to PLC 132indicating that the front edge of the stack of blanks has reached endwall 218. In response, PLC 132 can then initiate the tamping sequence to“square up” the stack of blanks, as detailed above.

In review, the tamping sequence for ensuring the blanks are properlysquared up at the pick up location steps, may include the followingsteps. The tamping actuator 276 may be extended having been activated bypressurized air controlled by PLC 132 and the associated valve. Then theside guide wall 201 may contract to make contact with the side of thecase stack and press the side wall 201 against the left hand side guidewall 200. This aligns the cases so the side edges of blanks are alignedwith each other and the longitudinal side wall of the walls 200 and 201.The tamping actuator 276 may then retract, and the tamping bar 280 pressthe stack forward, thereby aligning the blanks in the stack so thattheir front and rear edges are vertically aligned with each other andwith the inner face of the bar 280 and the inside surface of front wall218. The stack of blanks 111 is then properly positioned so that theerector heads 120 a and 120 b can begin picking up blanks from thestack.

One of the erector heads such as erector head 120 b will be positionedby the control of PLC 132 over movement apparatus 115 b, at the zeroposition calibrated for the head 120 b. PLC 132 may then cause servomotors 150 and 154 to be operated to achieve the following sequence ofoperations:

-   -   First the head 120 b may be moved to the pick up position as        shown in FIG. 17.    -   As the erector head 120 b is being brought vertically downwards        to retrieve the top blank on a stack of blanks 111 in magazine        110, the erector head's movement just prior to suction cups 312        contacting with the upper surface of the blank will be generally        vertically downwards. Prior to the suction cups 312 contacting        the surface of a panel A of a blank, sensor rod 380 will engage        the surface of panel A can cause sensor rod to be pushed        upwards. This movement upwards of sensor rod 380 relative to        plate 327 will physically cause the sensor to be activated and        send a signal to PLC 132. PLC 132 may respond to that signal by        causing servo drives 150 and 154 to slow down so that the final        few centimeters (e.g. 3.5 cm) of movement downwards towards        contact between cups 312 and the upper surface of panel A occurs        at a much slower rate. Also PLC knows how much further        vertically downwards erector head 120 b must be lowered to        establish proper contact between suction cups 312 and panel A.        It should also be that sensor rod 380 and associated sensor        device can also be used to ensure that PLC 132 is aware of        whether once a blank has been engaged in the magazine 110, it        stays engaged with erector head 120 until the appropriate        release location is reached, such as once erection of the carton        has been completed.    -   PLC 123 will also operate the valve device 340 on head 120 b to        cause suction force to be developed at suction cups 312 and        optionally also 320 (although suction at suction cups 320 can be        delayed);    -   With the head 120 b in the pick up position shown in FIG. 17 and        the suction force being applied at suction cups 312, the head        120 b can engage the panel A (see location of suction cup        outline on FIG. 10A) and then commence to lift upwards the blank        as shown in FIG. 18. PLC 132 will know how high to lift the        upper surface of blank 111, to ensure that once opened up, the        datum line W1 will be appropriately vertically located so that        components of folding and sealing apparatus 130 will be able to        fulfil their functions as described above.    -   Preferably when erector head 120 b has reached a determined        vertical position, and preferably while the erector head 120 b        is not moving longitudinally towards folding and sealing        apparatus 130, PLC 132 will send a signal to cause servo motor        134 to rotate which will then cause shaft 342 to rotate in a        particular desired direction at a particular desired rotational        speed for a desired amount of time. PLC 132 can control the        rotational position of shaft 342 to cause rotator device 350        which is fixedly attached to shaft 342 to rotate with shaft 342.        Thus rotator device 350 may be rotated to the position shown in        FIG. 19 and at that position suction cups 320, which will have        suction engaged, will attach to the underside of blank 111, and        in particular to panel D.    -   The next operation is the blank opening whereby through control        of PLC 132, opposed forces provided by suction cups 312 acting        upwards on top and suction cups 320 acting in an opposite        downward direction will start to pull the flattened blank apart.        The forces are then continued by the suction cups 312 above and        320 below, as rotator device 350 is rotated 90 degrees backwards        to the position shown in FIG. 20.    -   During the backwards rotation of rotator device 350, actuator        device 325 may be supplied with pressurized air controlled        through valve device 340 to activate the actuator device. PLC        132 may send a signal to valve device 340 to operate actuator        device 325 to extend piston arms 326 at a particular angular        position of arm 351 and or location of erector head 120 b that        is provided by the encoder associated with servo motor 364. PLC        342 may cause, acting through valve device 340, actuator device        325 to be actuated at approximately the same time as the cups        320 have contacted the surface of downward facing panel D and        the rotation of arm 351 is just about to begin or has just        commenced. Piston arms 326 may be completely extended by the        time arm 351 has rotated about 45 degrees. The piston arms 326        may continue to be extended and stay extended when rotator        device 350 is at the 90 degrees position shown in FIG. 20.    -   Once the blank 111 has been opened, erector head 120 b can        securely hold the blank by the suction forces exerted by cups        312 and 320, to panels A and D. Also, once opened the flaps K        and J need to be folded inwards towards the bottom opening of        the carton. In the embodiment shown in Figures such as FIGS. 17        to 29, the trailing minor flap K is closed by actuation of        paddle 310 as shown in FIG. 21. Thus PLC 132 can send a signal        to valve device 340 which causes rotary actuator 397 to rotate        shaft 316 and thus rotate paddle 310. Paddle 310 can then engage        trailing minor flap K of blank 111 and cause it to fold about        its fold line where it joins to panel D. Thus, flap K can be        folded inwards towards the bottom opening of blank 111.    -   Leading bottom flap J may also be folded about its fold line        which joins it with panel B by engagement of the flap with upper        and lower folding rails/ploughs 700, 701 that form part of        folding and sealing apparatus 130 as erector heads 120 b is        moved longitudinally downstream towards apparatus 130. As the        blank 111 held by erector head 120 b is moved longitudinally        downstream into the folding and sealing apparatus 130 the        leading bottom flap J can be folded inwards by rails/ploughs        700, 701, so that both bottom flaps K and J have been folded        inwards to start the formation of the bottom of the carton, as        is shown in FIG. 22.    -   Also when the flaps K and J have been folded inwards, under the        control of PLC 132, or pursuant to another control or trigger,        adhesive applicator 709 can through appropriately positioned        nozzles, apply a suitable adhesive at appropriate positions on        the flaps K and J such as shown. The application of glue can        occur before, during, or after PLC 132 has caused movement        apparatus 115 b to move erector head 120 b to a downstream        location where the major flaps F and G can be folded and        compressed onto minor flaps K and J. As shown in FIG. 23, glue        may be applied while movement apparatus 115 b is moving erector        head 120 b to the downstream location for closing the bottom        opening by folding and compression.    -   Next upper flap actuation device 705 may be activated by PLC 132        acting through a valve device to cause pneumatic actuator device        704 a to extend piston arms connected to an upper plough 708 a.        Similarly, lower flap actuation device 707 may also be activated        substantially simultaneously by PLC 132 such that pneumatic        actuator device 704 b extends its piston arms connected to lower        plough 708 b as shown in sequential FIGS. 24 and 25.

Next, as shown in FIG. 26, right hand compression device 706 with itscentral pneumatic actuator 710 may have piston arms extended so thatlongitudinally extending sealing plate 716 having attached theretolongitudinally extending upper rail 717 a, and lower rail 717 b engagesthe upper and lower major flaps F and J. Upper rail 717 a is positionedto be able to engage upper major flap F and lower rail 717 b ispositioned to engage lower major flap G when piston arms of actuatordevice 710 are extended horizontally and transversely inwards to pushflaps F and G into engagement with flaps K and J that are positionedunderneath. Upper and lower flap actuation devices 705 and 707 may bewithdrawn by PLC 132 when compression device 706 has engaged flaps F andG.

-   -   Next, as shown in FIG. 27, left hand compression device 704 may        be used to enter the carton from the left side and compress        flaps F, G, J and K between ram plate 720 of left hand        compression device 704 and the rails 717 a, 717 b of right hand        compression device 706. This compression assists in ensuring        that the panels are compressed together to ensure that the        adhesive appropriately bonds the flaps together to make a sold        carton bottom.    -   Once the compression has been held for a short time (for example        about 0.5 seconds) to allow the glue to sufficiently set/harden        and bond the flaps together, the compression can be released by        withdrawing left hand compression device 704 and right hand        compression device 706 as shown in FIG. 28. The carton is then        fully erected and released from both apparatus 130 and from        erector head 120 b as PLC 132 will cause suction cups 320 and        312 to have their suction force turned off by valve device 340.        Additionally, PLC 132 can cause rotator device 350 to be rotated        backwards a further 90 degrees to the horizontal ready position        shown in FIG. 29.    -   Thereafter, erector head 120 b can release the erected carton        which can then fall onto support plate 703 and remain there        until the next carton blank carried by another erector head        moved by another movement apparatus (such as erector head 120 a        moved by movement apparatus 115 a) moves the next carton blank        into the location where it will be folded, sealed and        compressed, and in doing so pushes the previous fully erected        carton downstream to chute 750 where it may fall onto discharge        conveyor 117.

The entire sequence of movement of a blank 111 as it is processed bysystem 100 is shown in isolation in FIGS. 10A-D, and FIGS. 11 to 16. InFIGS. 10A-D the blank is shown in its flattened tubular configuration.In FIG. 11 it is shown in its opened configuration after being opened byan erector head like erector head 120. In FIG. 12 it is shown with thetrailing minor flap K folded inwards and in FIG. 13 it is shown withleading minor flap J also folded inwards. In FIG. 14 blank 111 is shownwith the major bottom flaps F and G folded inwards and in FIG. 15 theblank is shown when the flaps J, K, F and G are being or have beencompressed to seal the bottom of the carton. Finally in FIG. 16 theerected carton is shown with its opening facing upwards so that it maybe loaded with one or more items.

While the foregoing handling of a carton blank 111 by erector head 120 bhas been occurring, erector head 120 a, being supported and moved bymovement apparatus 115 a, can be carrying out the same process but do soout of phase with erector head 120 b. For example, the cyclical movementand operation of erector head 120 a may be 180 degrees out of phase withthe movement and operation of erector head 120 b. By providing twoerector heads 120 a and 120 b operating simultaneously, but out of phaseso one does not interfere with the other, the processing capacity ofblanks can be increased significantly. But in using only one erectorhead 120, the processing capacity of the system 100 may still berelatively high. In part the relatively high processing capacity is alsodue to the relatively short “stroke” (i.e. longitudinal distance) thatthe erector heads must travel when carrying out the blank retrieval,erection, folding, sealing and compression. This means that thecomponents do not have to travel such a great distance as inconventional carton erectors. When using two erector heads with movingapparatuses, 100 may be capable of processing about 35 cartons perminute.

Many variations of the embodiments described above are possible. By wayof example only an alternate configuration for an erector head 1120 andfolding and sealing apparatus 1130 is shown in FIGS. 34a to 44.

With reference to FIGS. 34a and 34b , erector head 1120 is built insubstantially the same way as erector head 120 and functions in the sameway apart from the following major differences. Erector head 1120 doesnot include a paddle member like paddle 320 on erector head 120. As willbe described hereinafter, the component and functionality for closingminor trailing flap K of a blank 111 can be moved off the erector headand may become part of a modified folding and sealing apparatus 1130(see for example FIG. 36).

Erector head 1120 may have body generally designated 1330, that includesa bottom suction plate 1327 that is generally shaped in a square crossconfiguration to provide flanged openings for such cups. In each of theopen flanges of plate 1327 is positioned a suction cup 1312. Suctioncups 1312 are mounted with support blocks 1321 to a mounting plate 1322.Also mounted with mounting blocks is a suction cup 1313 and optionallycups 1315. Cups 1313 and 1315 may be employed to support a panel B of ablank 111 if the configuration of the panel and/or materials from whichblank 111 is made, require additional support for the blank 111 at leastwhen it is retrieved from the stack of blanks 111 in the magazine andeven until the rotary actuator device 1350 (which may be substantiallythe same as rotary actuator 350 on erector head 120) engages the bottompanel D of the blank prior to opening the blank.

In some applications, without the additional support provided by cup1313 and possibly cups 1315, the panels B and C may not remain in agenerally flattened configuration when the blank if picked up by cups1312 engaged with panel A.

It should be noted that suction cups and vacuum generators used onerector head 1120 may be same as used on erector head 120. Forsimplicity, electrical cables and hoses for pressurized air are notshown on erector head 1120 but like erector head 120 can be installed inappropriate locations.

Also, a valve device like valve device 340 above, to control the flow ofair is not shown but may be employed on erector head 1120 and may be inelectronic communication with PLC 132 and be controlled by PLC 132. Inthis way PLC 132 can turn on and off the supply of vacuum force to eachthe vacuum generators associated with each of the suction cups onerector head 1120.

The sequence of opening a blank using erector head 1120 is shown inFIGS. 35a, 35b, and 35c . Actuator 1325 may be actuated to reciprocatepiston arms 1326 between an extended position and a retracted position.PLC 132 may send a signal to valve device to operate actuator 1325 (likeactuator 325) to extend piston arms 1326 at a particular angularposition of arm 1351 and/or location of erector head 1120 b that isprovided by the encoder associated with servo motor 1364 (like servomotor 364). Similarly, PLC 132 may send a signal to valve device (notshown) to activate arms 1326 to be retracted at a particular shaft 1342angular position, and to retract piston arms 1326 at a particularangular position, of arm 1351 and/or a particular location of erectorhead 1120. PLC may cause, acting through valve device, actuator 1325 tobe actuated at approximately the same time as the cups 1320 havecontacted the surface of downward facing panel D and/or when rotation ofarm 1351 is just about to begin or has just commenced. Piston arms 1326may be completely extended by the time arm 1351 has rotated about 45degrees. At the same time or sometime before, rotary actuator 1350 isactivated to start the rotation, the PLC may through the valve devicecause suction to be released form suction cup 1313 to allow panel B ofblank 111 to rotate relative to panel A.

By way of further explanation, the two erector heads of system 100 caneach in turn be employed to engage and hold onto the top panel A ofblank 111. Once a blank 111 is retrieved from the top of the stack ofblanks, the rotator arm 1351 can be rotated approximately 180 degreessuch that suction cups 1320 of rotator device 1350 can engage and holdonto the underside panel D of blank 111. Once suction cups 1320 haveengaged panel D, suction at suction cup 1313 can be released and the arm1351 can be rotated 90 degrees backwards in the opposite rotationaldirection and the opposing vacuum forces created by suction cups 1312and possibly 1315 above, and suction cups 1320 below, can cause thetubular blank 111 to be moved from a flattened configuration to an openconfiguration as panel D is rotated substantially 90 degrees relative topanel A. The air suction force that may be developed at the outersurfaces of suction cups 1320 and 1312 and possibly 1315 will besufficient so that when activated they can engage, hold top panel A in astationary position relative to erector head 1120 and rotate panel Drelative to panel A to open up the tubular blank to a generallyrectangular configuration. The vacuum generated at suctions cups 1320,1312, 1313 and possibly 1315, can also be de-activated by PLC 132 atappropriate times by sending signals to valve device, such as when it isappropriate to release the fully erected carton.

As with erector head 120, on erector head 1120, opening of the blank 111may be assisted by the extension of piston arms 1326 of actuator device1325 during rotation of the rotator arm 1351. Preferably when rotatorarm 1351 has rotated somewhere in the range of about 30-60 degrees backto the 90 degree position, and preferably when it is at approximately40-50 degrees, and most preferably when it is at about 45 degrees, thenthe piston arms 1326 may be fully extended. This extension of arms 1326and thus of suction cups 1320 in a generally tangential directionrelative to the rotation of arm 1351 compensates for the offset of theaxis of rotation of the arm 1351 compared to the axis of rotation of theblank that extends along the fold line between panels A and D. Theeffect of the extension of piston arms 1326 once the arm is rotated suchas to 90 degrees ensures that the panel D is also oriented at 90 degreesto panel A.

Another feature of erector head 1120 that can be noted is that a cartonlocation sensor apparatus may be provided and may include areciprocating sensor rod 1380 which, when not in contact with a blank,extends downwards through an aperture 1381 in plate 1327, below thelevel of the plane of suction cups 1312. In a manner similar to sensorrod 380 in erector head 120 b, when the erector head 1120 is broughtvertically downwards to retrieve a blank on a stack of blanks 111 inmagazine 110, the erector head's movement just prior to suction cups1312, 1313 and possibly 1315, contacting with the upper surface of theblank will be generally vertically downwards. Prior to the suction cupscontacting the surface of a panel A of a blank, sensor rod 1380 willengage the surface of panel A which can cause the sensor rod to bepushed upwards. This movement upwards of sensor rod 1380 relative toplate 1327 will physically cause a sensor (not shown) to be activatedand send a signal to PLC 132. Like in the previous embodiment, thesensor may be an inductive proximity sensor. The metal cylinder fixed onthe rod is sensed by the sensor's circuitry because it changes theinductance of the induction loop inside the sensor. The sensor may be871FM-D8NP25-P3 made by ALLEN BRADLEY. PLC 132 may respond to thatsignal by causing the movement apparatus (not shown but may be likeapparatus 115 b) to slow down so that the final few centimeters (e.g.3.5 cm) of movement downwards towards contact between cups 1312 and theupper surface of panel A occurs at a much slower rate and also PLC knowshow much further vertically downwards erector head 1120 must be loweredto establish proper contact between suction cups and panel A. It shouldalso be that sensor rod 1380 and associated sensor device can also beused to ensure that PLC 132 is aware of whether once a blank has beenengaged in the magazine 110, it stays engaged with erector head 1120until the appropriate release location is reached, such as once erectionof the carton has been completed.

With reference now to FIGS. 36 to 44, it will be observed that unlikewith erector head 120, with erector head 1120, each opened blank ismoved towards folding and sealing apparatus 1130 to fold both leadingminor panel J and trailing minor panel K with the folding and sealingapparatus 1130.

Folding and sealing apparatus 1130 mounted to a plate 1175 forming partof frame 1109 may be constructed in the same manner as apparatus 130mounted to frame 109, as described above. However, apparatus 1130 may beprovided with an angled paddle device 1310 that is connected to a distalend of a paddle arm 1314, that may be mounted to frame 1109. Paddle arm1314 may be connected to a shaft 1316 a rotary actuator 1399 forrotation therewith. The rotary actuator may be a double acting rotarypneumatic actuator manufactured by Festo under engineering part #DSM-32-270-CC-FW-A-B. Actuator 1399 can cause rotation of arm 1314clockwise and counter-clockwise around its axis of up to 270 degrees.Rotary actuator 1399 may be supplied with pressurized air supplied byhoses (not shown) connected to ports 1395 and 1397. Those hoses may alsobe connected to a solenoid valve device (not shown) which may becontrolled by the PLC 132. In this way the rotation clockwise andcounter-clockwise of paddle 1310 may be controlled by PLC 132.

Once a blank 111 has been opened to the configuration shown in FIG. 36,then PLC 132 can send a signal to cause erector head 1120 to movetowards apparatus 1130. As shown in the sequence of FIGS. 37 to 39,initially, leading minor flap J will be engaged by ploughs 1700 and 1701to fold flap J inwards. While or after that is being completed, as shownin the sequence in FIGS. 40 to 42, next the valve device can causeactuator 1399 to rotate shaft 1316 and thus rotate arm 1314 with paddle1310 attached thereto. Paddle 1310 can then engage trailing flap K ofblank 111 and cause it to fold about its fold line where it joins topanel D. Thus flap K can be folded inwards towards the bottom opening ofblank 111. Thereafter as shown partially in FIGS. 43 to 44, the cartonblank 111 held by erector head 1120 b can be moved longitudinallyfurther downstream into the folding and sealing apparatus 130 where theminor flaps may be glued and the major top and bottom flaps F and G maybe folded inwards and compressed, in substantially the same manner asdescribed above in relation to erector head 120 b and movement apparatus115 b.

The particular arrangement of suction cups and rotating paddle onerector heads 1120 can be designed based upon the configuration of thecarton blank and the particular panels and flaps that need to berotated. It will also be appreciated that on erector head 1120 that isillustrated, suction cups are used to apply a force to hold and/orrotate panels of a carton blank. However alternative engagementmechanisms to suction cups may be used.

In some embodiments, the flaps of the blank may be sealed by means otherthan a glue applicator. For example, it is possible to configure foldingand sealing apparatus with an adhesive tape applicator that may applytape to the bottom of the box once all minor and major flaps have beenfolded. In such an embodiment, compression of the flaps at the bottom ofthe erected carton may not be necessary. An example of such a set up isillustrated in FIGS. 50 to 52. In this embodiment the folding andsealing stations like station 130 have been replaced by a folding andsealing station that includes a middle plough for folding a leadingminor flap. Thus both minor flaps can be closed by the middle plough forthe leading minor flap and a paddle device like those described abovefor the trailing minor flaps. Upper and lower ploughs can be provided tofold over top of the minor flaps and then the moving apparatus can movean erector head 120 carrying an opened and flap folded blanks againstthe operational surface of an adhesive tape applicator. An example of atape applicator that could be adapted for such use is a model Z59-557supplied by Dekka Industries Inc. The folded bottom of the opened blankcan then be moved longitudinally against the carton blank and tape couldbe started to be applied at a lower portion of panel B, over and alongthe middle join between flaps F and G, and the terminate at a lowerportion of panel D.

In another embodiment, shown only schematically in FIG. 45, the systemcould be modified to employ one or more moving apparatuses 2115 a, 2115b that may be substantially the same as moving apparatus 115 a, 115 b,and a magazine 2110 that may be substantially like magazine 110.However, folding and sealing apparatus 130 or 1130 could be replaced/oranother device could be inserted above a support plate 2703 that has adischarge chute 2750. A blank shoe device 2130 may be configured withinterior guides. Erector head 2120 a, 2120 b, may be simplified devicescontrolled by PLC 132 which have only four suction cups 2130 that may bearranged in a generally rectangular configuration. Erector heads 2120 a,2120 b may be readily interchanged in system 100 illustrated anddescribed above for erector heads 120 a, 120 b and PLC 132 may operateanother sequence of operations on erector heads 2120 a, 2120 b toprocess a blank 1111 (see FIG. 46) that may be used to form an open toptray. Suction cups 2130 may engage a blank 1111 that is configured to beformed into an open top tray. The moving apparatuses 2115 a/b may move ablank secured to a head 2120 a/b longitudinally from the magazine whereit is retrieved from a stack of blanks, through opposed glue applicators2709 which may apply a suitable adhesive to flaps and then move theblank above shoe device 2130. The moving apparatus may then move theblank downwards through the shoe device 2130 causing the flaps to befolded and they can be held within the shoe for a sufficient time toallow the glue to set. Thereafter continued movement downwards can pushthe blank clear of the shoe device 2130 and then suction cups canrelease the blank which can then fall onto support plate 2703.Thereafter the blank can be moved for example by a blow-off nozzledischarging high pressure air (under control of PLC 132 through a valvedevice interposed in pressurized air hoses) to discharge the blank tochute 2750 for transfer to a discharge conveyor.

It will be appreciated that by making a relatively small number ofchanges to the components of the system, the system can be altered frombeing able to process blanks for open top cartons to being able toprocess blanks that can be turned into open top trays. Examples of otherblanks that may be processed, cartons that may be formed are illustratedin FIGS. 47, 48 and 49 and include blanks for wrap around half slottedcases (HSC) and HSC blanks, as well as blanks for a wrap around RSC.

Turning now to FIG. 58, an order fulfilment system generally designated1000 may include several components including an order fulfilmentprocessor 1300, and corresponding sets of case formers 1100A, 1100B and1100C, case loaders 1400A, 1400B and 1400C and case sealers 1500A, 1500Band 1500C. A plurality of customer order devices 1200A, 1200B and 1200Cmay be provided that may be linked with order fulfilment processor 1300.Customer order device 1200A may for example be a telephone that may becapable of communication with a call center 1250. Call center 1250 maybe adapted to receive orders from customer operating customer orderdevice 1200A and then by virtue of call center software, a call centeroperator may input an order for one or more products that may becommunicated by a communication link to order fulfilment processor 1300.Customer order devices 1200B and 1200C may for example be personalcomputing devices including mobile phones, personal computers, etc. thatmay be capable of direct communication such as by communication over awireless and/or land-based communication network with order fulfilmentprocessor 1300. This network may, for example, an IPv4, IPv6, X.25, IPXcompliant or similar network. Thus, this network may be the publicInternet. Through operation of appropriate software on the customerorder devices 1200B, 1200C and order fulfilment processor 1300, thecustomer order devices 1200B, 1200C may be adapted to input an order forone or more products into order fulfilment processor 1300. For example,customer order devices 1200B and 1200C may be adapted to execute asuitable HyperText Transfer Protocol (HTTP)-enabled browser to accessdata and services provided by an HTTP server application executed byorder fulfilment processor 1300, and thereby input orders for one ormore products into order fulfilment processor 1300.

Order fulfilment processor 1300 may be a mainframe computer, a server,or other computing device capable of processing customer orders receiveddirectly or indirectly from customer order devices 1200A-C. Orderfulfilment processor 1300 may include a database that includesinformation that may be stored in a suitable memory therein includinginformation relating to: (a) information/details of all products thatmay be ordered by a customer through system 1000 including one or morecharacteristics of each product such as the physical volume occupied bythe space and/or the actual physical dimensions (e.g. height, width,length, and/or diameter) of each product (such as the dimensions of thebox in which one or more items is held), optionally the weight of eachproduct, and further optionally product codes associated with eachproduct, such as a Universal Product Codes (UPC) or, if the product is abook, an International Standard Book Number (ISBN); (b)information/details of each of a plurality of types/sizes/configurationsof cases/case blanks that can or are being used in system 1000 topackage one or more products ordered by a customer including thedimensions of each type of case/case blank; (c) information/details ofeach case former (e.g., case formers 1100A-C), includinginformation/details of the cases that each case former is capable offorming (such as the type, size and/or configuration), and optionallywhen a case former includes multiple magazines, as detailed below, thetype, size and/or configuration of case blank provided in each of thosemagazines and the corresponding type, size and/or configuration of casethat can be formed from each type of case blank, and further optionallythe quantity of case blanks provided in each of those magazines; (d)information/details about each customer including the name of the entityand shipping address to which an order fulfilled by system 1000 is to beshipped and (e) information/details about where each product is locatedin a product storage facility such as a warehouse building holdingproducts that may be ordered.

As noted, order fulfilment processor 1300 may also include an HTTPserver application adapted to provide database information to customerorder devices 1200B and 1200C, and to receive orders from customer orderdevices 1200B and 1200C. Some or all of the aforementionedinformation/details may be input into order fulfilment processor 1300manually by an operator of system 1000. Additionally or alternativelywith respect to information/details of each available case may beupdated periodically or on an ongoing basis. PLC 132 of each cartonformer 1100A-1100C may during operation, be adapted to monitor thestatus of the case blanks in its magazine(s) and provide informationrelating to that status to order fulfilment processor 1300. In this way,order fulfilment processor 1300 may be continually provided withup-to-date information on available case blanks that are in themagazines of each of the carton formers.

Order fulfilment processor 1300 may also include a product packagingutility/product packaging software module that identifies a suitabletype of case (or types of cases) for packaging the products in an orderplaced by a customer from a plurality of available cases. An example ofsuch a product packaging utility is disclosed in U.S. Pat. No. 6,876,958to Chowdhury et al., issued to assignee New Breed Corporation on Apr. 5,2005 (hereinafter, “Chowdhury”), the contents of which is herebyincorporated by reference herein in its entirety. In particular,Chowdhury's product packaging utility processes each order placed by acustomer to automatically identify, from available casetypes/sizes/configurations, a type/size/configuration of suitable case(or cases) suitable for packaging the products in the order. Chowdhury'sproduct packaging utility identifies/determine suitable case(s)according to an algorithm/function that accesses and uses one or moreelectronically-stored characteristics of each product in the order(e.g., dimensions, weight, etc.) and one or more electronically-storedcharacteristics of available case types (e.g., dimensions, size,configuration, type, maximum volume that can be held, maximum weightthat can be held, etc.). This algorithm identifies suitable cases suchthat a minimum number of cases and the smallest size cases suitable forpackaging the products in the order may be provided. Thus,identification of suitable case types/sizes/configurations can beoptimized to provide an optimal case type/size/configuration whichminimizes packaging material used and to minimize empty space in cases,and a case identified as suitable may be referred to as an “optimal”case. It will be appreciated that identification of suitable casetypes/sizes/configurations may also be identified or optimized accordingother pre-defined criteria. The case identification algorithm ofChowdhury's product packaging utility may also take into account otherfactors and constraints such as, e.g., the availability of eachtype/size/configuration of case, the maximum fill ratio of eachtype/size/configuration of case, the maximum number of products that canbe placed into each type/size/configuration of case, and whether certainproducts are pre-packaged together and therefore must be placed in thesame case. Thus, when order fulfilment processor 1300 includes a productpackaging utility such as Chowhury's product packaging utility, orderfulfilment processor 1300 may process a customer order for specificproducts by accessing information in it memory and utilizing analgorithm/function to identify a suitable case (or cases) for packagingthose products from a plurality of available cases.

It should be noted that the size of the case may be the overall internalavailable volume of the case in which items may be held. The size mayalso be the specific dimensions of the case. The type of case mayinclude the reference to what material the blanks is made from (e.g.paperboard or corrugated cardboard). Its configuration may an indicationof it being a top opening case which is generally cuboid in shape whenclosed, or another configuration such as a regular slotted case, etc.

Chowdhury's product packaging utility may also generate, for each caseof a particular type/size/configuration identified to fulfil an order, apacking list indicating the order in which each of the products is to bepreferably placed into the case, as well as placement informationindicating where each product is to be preferable placed in the case.For example, this placement information may be expressed usingcoordinates (e.g., 0, 0, 0) in a coordinates system defined for the caseand/or descriptors of locations in the case (e.g., front, right handside, second layer, etc.). Thus, when order fulfilment processor 1300includes a product packaging utility such as Chowdhury's productpackaging utility, order fulfilment processor 1300 may generate apacking list and/or placement information for each identified case.Order fulfilment processor 1300 may also generate a diagram illustratinga desired optimal physical arrangement of the products in each case.Such a diagram may be readily generated using placement coordinates foreach product, as provided by Chowdhury's product packaging utility.

For each case of a particular type identified to fulfil an order, orderfulfilment processor 1300 may also be configured to be able to selectone of case formers 1100A, 1100B or 1100C to form a suitable case of thetype/size/configuration identified by order fulfilment processor 1300.Order fulfilment processor 1300 may access and use information stored inits memory regarding the suitability of the case formers to handle anidentified suitable case. For example, suitability of a case former maybe determined by order fulfilment processor 1300 based on storedinformation regarding whether the case former includes magazinesdesignated to hold the types/size/configuration of case blanks requiredforming the identified case. Suitability of a case former may also bedetermined based on stored information regarding the quantity of therequired type/size/configuration of case blank in a magazine of the caseformer. Such quantities may be measured using suitable sensors placed ateach case former, and updated during operation. Alternatively, orderfulfilment processor 1300 may simply select a case former randomly oraccording to a pre-defined sequence.

Once a suitable case former (e.g., one of case formers 1100A, 1100B or1100C) has been selected, order fulfilment processor 1300 may generate aFulfilment Order data structure (e.g. a file, object, message or thelike) containing information for/instructions to the case former to formand label a required case. A generated Fulfilment Order data structuremay be communicated by a communication link to the PLC of one of thecase formers 1100A, 1100B or 1100C.

The Fulfilment Order data structure may include indicators indicating(i) the type/size/configuration of case determined by the productpackaging utility that is required to be formed and labelled by the caseformer 1100A, 1100B, 1100C; (ii) the particular magazine of the caseformer containing case blanks for forming the required suitable case;(iii) a list of the particular product(s) from the customer order beingfulfilled that are required to be loaded into the required case onceformed, optionally identified by associated product codes and optionallyarranged in the order in which the products should be loaded into thecase once formed; (iv) optionally information such as packing list or adiagram illustrating/specifying a desired optimal physical arrangementof the products in loading the case; (v) optionally the location in thestorage facility/warehouse building of each particular product from thecustomer order being fulfilled; and (vi) customer shipping informationfor that case indicating the destination name and address for that case.In some cases, the Fulfilment Order data structure may includeinformation for multiple cases to be handled by the selected caseformer.

A Fulfilment Order data structure may be received and processed by thePLC of the case former to which the data structure is sent. Inparticular, the PLC of the case former processes the Fulfilment Orderdata structure to identify a requested type/size/configuration of case(or cases) to be formed, the particular magazine of the case formercontaining case blanks for forming each required case, and the contentsof the label (or labels) to be applied. Once a required suitable caseand the particular magazine containing case blanks for forming therequired suitable case have been identified, the PLC of the selectedcase former 1100A, 1100B or 1100C can then cause a suitable case blankto be formed into the requested type/size/configuration of case andlabelled, as further described hereinafter.

Optionally, the data structure may be stored in memory of the PLC of thecase former or in memory of order fulfilment processor 1300 for laterretrieval when the order is picked and packed, as described below.

Once the case has been formed and labelled for a particular customerproduct order, it may then be physically transferred to a respectivecase loader generally designated 1400A, 1400B or 1400C. In someembodiments, the formed and labelled case can be picked up by a person(referred to herein as an Order Fulfilment Picker or “OFP”) who may bein a product storage facility (e.g. a warehouse building) filled withthe products handled by order fulfilment system 1000. OFP may have orcarry a label scanner device 1407 (see FIG. 62B) which may include ascanner 1411 and an interconnected display device 1409. Examples ofsuitable label scanning devices that could be employed include the modelLT5020H made by Worth Data Inc. (Santa Cruz, Calif., USA).

Label scanning device 1407 may be a bar code reader adapted to scan andderive information from the label or labels applied to the case.Optionally, label scanning device 1407 may be connected to one or otherof the PLC of the case former or order fulfilment processor 1300 by acommunication link. In such instance, some or all of the information fora case may retrieved by label scanning device 1407 from the PLC of thecase former or from order fulfilment processor 1300 using a caseidentifier encoded in bar codes on the label(s) applied to the case.

The OFP may for example scan the bar codes on the label(s) on the casewhich may enable the OFP to identify the particular products that are tobe loaded into that case. Optionally, scanning these bar codes may alsoenable the OFP to identify where the particular products are located inthe warehouse building. The OFP may then load the case into a cart 1413(FIG. 62B) and then proceed to locate the products in the warehouse andfill the case with those products, possibly in the order listed by thescanning device 1407. Optionally, a packaging arrangement diagram (suchas the diagram of FIG. 61) either illustrated on the label on the case,or optionally displayed on a device such as the label scanner, ifavailable, may be provided to and used by the OFP to load the case in adesired optimal manner. An example of a packaging arrangement diagramthat can be utilized to load a case is illustrated in FIG. 61. A case,formed from a blank, and having dimensions of width W, height H andLength L, can be loaded as shown with items (i.e. products) numbered 1to 6 arranged in a particular arrangement and may also include someadditional dunnage or packing material (e.g. bubble wrap type material)that may be inserted by an OFP to maintain the stability and integrityof the items in the packaging arrangement during shipping to thecustomer.

In other embodiments, one or more of the case loaders 1400A, 1400B,1400C may include automated equipment such as one or more roboticsystems instead or in addition to an OFP.

Turning now to FIGS. 53 to 57, case former 1100 (representative of eachof case formers 1100A-C) may comprise the same or substantially the samecomponents as carton forming system 100 as described above, except wheredifferences are hereinafter described. Like in carton forming system100, the structural/mechanical components of carton former 1100 may bemade from any suitable materials. Case former 1100 is particularlyuseful as part of a customer order fulfilment system 1000 that mayfulfil product orders placed or initiated by customers as describedabove. However, carton former 1100 may also be used in otherapplications.

As an alternate to a magazine like magazine 110 in carton forming system100 as described above, case former 1100 may include or utilize aplurality of magazines such as magazines M1-M16. Magazines M1-M16 mayeach contain one or more stacks of product packaging, such as caseblanks which each may generally be like blanks 111 processed by system100, with at least some of the magazines M1-M16 containing differenttypes/sizes and/or configurations of packaging/case blanks to othermagazines. The size, configurations and types of case blanks (and thecases that can be formed therefrom) can vary to provide a range of casesizes, configurations and types that can be automatically processed bycarton former 1100 without the need for any manual intervention tomodify any components of the case former 1100. PLC 132 of case former1100 may be programmed such that the particular dimensions/overallsize/configuration (e.g. such as regular slotted carton or “RSC”)/typeof each of the blanks held in each one of the magazines M1-M16 is storedin the memory of the PLC 132.

It should also be noted that case former 1100A, 1100B, and 1100C mayeach be configured with magazines having a different set/selection ofsizes/configurations/types of case blanks from that of the othermagazines, so that each of the carton formers 1100A, 1100B, 1100C areoperable to process different cases. Case formers 1100A, 100B, and 1100Cmay be configured with magazines such that they collectively process apre-defined set of case blanks types that provides a range of casesizes, configurations and types.

Each magazine M1-M16 may have its own blank transfer apparatus that mayeach include a transversely oriented magazine conveyor 1203(1) to1203(16) respectively. Each conveyor 1203(1) to 1203(16) (referred togenerically as a magazine conveyor 1203) may be controlled by PLC 132 ofits carton former 1100, such that a stack of blanks in each magazineM1-M16 may be moved to a position adjacent a longitudinally oriented,central case blank in-feed conveyor 1204. Each magazine M1-M16 may havea transfer apparatus under the control of PLC 132 that is operable toextract and move a blank from a stack in the magazine M1-M16 adjacent toin-feed conveyor 1204 and feed it onto central in-feed conveyor 1204 tothat it may be transported to be labelled as described hereinafter, andalso folded and sealed in a manner like that described above inconnection with system 100.

With reference now to FIG. 54A, by way of representative example of theconstruction of a magazine, magazine conveyor 1203(1) may include aframe 1215 that supports five, generally parallel, and spaced continuousbelts 1213 that may be made of any suitable flexible material such asRopanyl. The belts 1213 may each extend between rotatable idler wheels1221 mounted on a freely rotatable shaft and rotatable drive wheels1223. Drive wheels 1223 may be mounted for rotation with and to a commondrive shaft 1225 of a servo motor 1219 that may be interconnected viaand in communication with a servo drive to the PLC 132 of the caseformer 1100. Conveyor belts 1213 may each have an upper belt portionthat together may support one or more stacks of blanks 1211 thereon. PLC132 may give an instruction (such as by order fulfilment processor 1300)to form a case, and if required, PLC 132 may cause upper belt portion ofbelt 214 to move towards in-feed conveyor 1204 by operation of servomotor 1219 rotating drive wheels 1223. In this way belt 214 can, ifnecessary, move a stack of blanks 1211 to a position adjacent to thein-feed conveyor 1204.

Positioned proximate the end of each magazine conveyor 1203 adjacentin-feed conveyor 1204 may be a vertically and longitudinally orientedplate 1230. Each plate 1230 may be supported by a plurality of platesupport members 1235 that may be part of frame 1215. A lowerlongitudinally extending edge 1233 of plate 1230 may be positioned sothat only the bottom blank in a stack of blanks (i.e. the blank that isimmediately above the upper portions of the belts) can pass through aslot provided beneath lower edge 1233 of plate 1230 and the horizontalplane formed by the upper surface of the upper portions of the belts1213. In this way, a slot 1231 can be provided that can permit a singleblank at a time from the bottom of the stack to be pushed transverselythrough the slot and onto the in-feed conveyor 1204.

A pushing mechanism may be provided to respond to signals from PLC 132of the case former to push a blank in a magazine from the bottom of thestack though the slot 1204 and onto in-feed conveyor 1204. The pushingmechanism may be any suitable type of device and may for example includea plurality of lugs 1217 located in the spaces between belts 1213. Thelugs may be driven in a cyclical path by a common type crank mechanism(not shown) that may include a common pneumatic or hydraulic cylinderwith a piston controlled by PLC 132 by activating appropriate valves tosuitably control the flow of pressurized air/hydraulic fluid to thecylinder. The cylinder may have a piston arm attached to alongitudinally oriented bar member that may be mounted for rotation. Thecrank mechanism may be configured to provide a path for the lugs 1217that commences in a position behind the bottom blank in a stack; thenmoves transversely between the belts 1213 while engaging the rear sideedge of the bottom blank thereby pushing the bottom blank through theslot 1231. Once the crank mechanism reaches the end of the stroke, thelugs 1271 will descend downwards beneath the stack of blanks and movetransversely in an opposite direction back to the starting position,while at the same time not engaging the next bottom blank on the stackand passing beneath the stack. The path returns the lugs 1217 back tothe start position so that when signalled by PLC 132 to load anotherblank onto conveyor 1204, the operation can be repeated.

In summary, PLC 132 can thus control motor 1219 and thus the movement ofeach conveyor 1203 as well as the movement of the lugs 1281, and thus isable to selectively move and transfer a single blank at a time ontoin-feed conveyor 1204 from any one of magazines M1 to M16

Therefore, unlike in system 100 where a stack of case blanks may be fedto the alignment conveyor 206 by in-feed conveyor 204, in system 1000separate individual case blanks may be fed in series and longitudinallyby in-feed conveyor 1204 to alignment conveyor 1206. The particularsequence/order of case blanks that are placed onto in-feed conveyor 1204of each case former 1100A-C may be determined and selected by PLC 132such that case blanks may arrive at alignment conveyor 1206 in such adesired manner in which it is desired to process the blanks at leastwithin case former 1100.

Further, each PLC 132 may maintain in its memory records of case blanksthat have been placed onto in-feed conveyor 1204, to be formed andlabelled. Each record may include information received by PLC 132 fromorder fulfilment processor 1300 (e.g., by way of the Fulfilment Orderdata structure) for a particular case blank to be formed and labelled.For example, this information may include the type/size/configuration ofthe case blank and the label information to be applied to the caseblank. A new record can be added each time a request for a new case isreceived from order fulfilment processor 1300 and optionally records canbe removed once a case has been formed and labelled. Thus, such recordsmay be organized and maintained in sequence in the memory of PLC 132using a conventional shift registering technique. In this way, therecord for the next case blank scheduled to arrive at alignment conveyor1206 may be provided at the output of the shift registers as that caseblank arrives, and the type/configuration/size of that case blank andthe label information for that case blank may be determined from theprovided output.

Once transferred from in-feed conveyor 1204 to alignment conveyor 1206,the alignment conveyor 1206 may then under the control of PLC 132 moveeach blank sequentially to the pick up location. The pick up locationmay in part be determined by the front edge of each blank abutting thesurfaces of a pair of spaced vertical plates 1218 (FIG. 57) as they aremoved longitudinally downstream by alignment conveyor 1206.

Conveyor 1204 may be constructed substantially like conveyor 204 mayinclude a pair of spaced conveyor belt 214 that may be driven by asuitable motor such as a DC motor or a variable frequency drive motor.The motor may be DC motor and may be controlled through a DC motor drive(such as are all sold by Oriental under model AXH-5100-KC-30) by PLC132.

Conveyor belts 214 may have an upper belt portion supported on rollers(not shown). PLC 132 can as required cause upper portions of belts 214to move longitudinally downstream towards alignment conveyor 1206. Inthis way belts 214 can move a series of spaced apart case blankslongitudinally downstream. PLC 132 can control the motor drivingconveyor 1204 through the motor drive and thus conveyor 1204 can beoperated to move and transfer a series of blanks obtained from multiplemagazine of magazines M1 to M16 towards and for transfer to thealignment conveyor 1206.

Blank alignment conveyor 1206, like alignment conveyor 206, may alsoinclude a series of transversely oriented rollers 1208 that may bemounted for free rotating movement to a lower portion of the magazineframe 202. A conveyor belt 1216 may be driven by a motor that and have acorresponding motor drive. This motor and motor drive for conveyor 1206may also be controlled by PLC 132. Belt 1216 may be provided with anupper belt portion supported on rollers 1208 and upon which one or morecase blanks may be supported. Conveyor belt 1216 may be operated to moveeach case blank in turn further longitudinally until the front face ofthe blank abuts with a generally planar, vertically and transverselyoriented inward facing surface of upstanding spaced plates 1218 so thateach case blank is in turn placed into the pick up position.

Conveyor belt 1214 of conveyor 1204 and conveyor belt 1216 of conveyor1206 may be made from any suitable material such as for example Ropanyl.

A sensor (not shown) such as an electronic eye model 42KL-D1LB-F4 madeby ALLEN BRADLEY, may be located within the horizontal gap between belt1214 and belt 1216. The sensor may be positioned and operable to detectthe presence of the front edge of a blank as each blank in turn beginsto move over the gap between conveyor belt 1214 and conveyor belt 1216.Upon detecting the front edge, sensor may send a digital signal to PLC132 signalling that a particular blank (the size/configuration/type ofwhich PLC 132 is aware) has moved to a position where conveyor 1206 canstart to move. PLC 132 can then cause the motor for conveyor 1206 to beactivated such that the top portion of belt 1216 starts to move theblank downstream. In this way, there can be a “hand-off” of each blankfrom in-feed conveyor 1204 to alignment conveyor 1206.

Once the rear edge of each blank passes the sensor, a signal may be sentto PLC 132 which can then respond by sending a signal to shut down themotor driving belt 1214 of conveyor 1204. Conveyor 1204 is then in acondition to await a further signal thereafter to feed the next blank inthe series of blanks on the conveyor 1204 to alignment conveyor 1206.Meanwhile alignment conveyor 1206 can be operated to move the blankplaced thereon to the pick up location.

The presence of a blank on alignment conveyor 1206 at the pick uplocation may be detected by another sensor that may be the same type ofsensor as sensors 240 and 242. The sensor may detect the presence of thefront edge of a blank at the pick up position and may send a digitalsignal to PLC 132 signalling that a blank is at the pick up position. Atthe pick up position, the blank may also be centred longitudinally by apair of moveable longitudinally oriented side wall guides 1201 and 1202.

Each blank may be suitably longitudinally and transversely positionedand oriented in a pick up position for proper engagement by both alabelling device and by one of the erector heads like erector heads 120a, 120 b of system 100. Side guide walls 1201 and 1202 may be mounted toon tracks to a lower portion of a lower frame and both may be orientedgenerally vertically and may extend longitudinally for substantially thefull length of alignment conveyor 1206. The side guide walls 1201, 1202may be mounted in a similar manner as side walls 200, 201 in system 100.

A drive mechanism may be provided to drive each of side walls 1201 and1202 on respective tracks. For side walls 1201 and 1202, one or moredrive mechanisms that are in electronic communication with PLC 132 canbe provided. By way of example, a servo motor 258 (FIG. 1B) with gearhead may be provided and be in electronic communication with PLC 132through a servo drive. Examples that could be used are servo motorMPL-B1530U-VJ42AA made by ALLEN BRADLEY, in combination with servo drive2094-BC01-MP5-S also made by ALLEN BRADLEY and gear head AE050-010 FORMPL-A1520 made by Apex.

Like in carton forming system 100, in case former 1100 lead screw rodsmay be inter-connected to servo motor/gear heads. Lead screw rods maypass through nuts, which may be fixedly secured to plates. Plates may beinterconnected to spaced, generally vertically oriented bar members. Barmembers may be interconnected to support frame (not shown) forming partof side walls. By activating servo motor/gear heads, the rotation of theservo may rotate the screw rods. As rods passes through nuts, the nutscan be moved laterally either inwards or outwards, thereby causing walls1201, 1202 to slide on tracks inwards or outwards depending upon thedirection of rotation of screw rods. Encoders may be provided within orin association with servo drive motors and the encoders may rotate inrelation to the rotation of the respective drive shaft of the servodrives. The encoders may be in communication with, and provide signalsto the servo drives which can then pass on the information to PLC 132.Thus, PLC 132 may be able to determine the longitudinal position of thescrew rods in real time and thus the transverse position of side walls1201, 1202 and can operate the servo drives to adjust the position ofthe side walls 1201, 1202. The particular type of encoder that may beused is known as an “absolute” encoder. Thus once the encoders arecalibrated so that a position of each the screw rod is “zeroed”, theneven if power is lost to system 1000, the encoders can maintain theirzero position calibrations. With the transverse alignment mechanism ofside guides walls 1201, 1202 in abutment with the left and right sideedges of the blank, guide walls can ensure he proper positioning of thedatum line when the blanks are flattened is properly transverselyaligned to be labelled by labelling device 1281 (only shown in FIG. 57)and to be picked up by erector heads 120 of system 1100 and movedthrough folding and sealing apparatus 130, as described above to achieveproper folding and sealing of the carton/case blank.

Optionally, PLC 132 may verify that the type/size/configuration of thecase blank at the pick up location matches the expected case blank. Forexample, the top surface of each case blank may include a bar codeidentifying its type/size/configuration, and this bar code may be readat the pick up location by a suitably positioned bar code reader. Thetype/size/configuration of the case blank read from this bar code may becompared to the expected type/size/configuration of case blank, whichmay be determined from a record of the next scheduled case blank storedin memory of the PLC, as described above. Verification is successfulwhen there is a match. When there is not a match, PLC 132 may issue asignal requesting manual operator intervention.

As indicated above, each case blank in each magazine may be generallyinitially formed and provided in a flattened tubular configuration suchas by way of example is shown in FIGS. 10A-10E. Each case blank has aheight dimension “H”; a length dimension “L”; and a major panel length“Q” (see FIG. 10B). The PLC of each case former 1100 may maintain in itsmemory each of these three dimensions for a case blank to be processedby case former 1100, and using these stored dimensions, the PLC candetermine the necessary positions and/or movements of at least some ofthe components forming system 100, including the path of movement oferector heads 120 a, 120 b as the erector heads move and cycle throughtheir processing sequences.

In this regard, for each case blank in each of magazines M1 to M16, PLC132 may have the information necessary to adequately process each caseblank selected.

As was indicated above in relation to a representative case blank asshown in FIG. 11, each case blank in each magazine may be designatedwith a first datum line “W1” that passes through the mid-point of thefold line between panel D and flap K, and the mid-point of the fold linebetween panel B and flap J. This datum line W1 may be determined by PLCfor blank to be processed, based on the dimensions H, L and Q of theblanks stored by the PLC or obtained by the PLC. Blank 111 may also bedesignated with a second datum line “W2” that may be determined by PLC132 and which passes along and is generally parallel to the fold linebetween panel D and flap K, and the mid-point of the fold line betweenpanel A and flap F. Datum W1 will be parallel to Datum W2. PLC 132 mayalso determine the relative position of the bottom of the erected casefor the cases in each magazine as this will be aligned with a verticaldatum plane passing through Datum W1 and Datum W2. Aligning the positiondatum W2 and of the datum plane with other components in case former1100 will ensure that the case is properly positioned during processing.Also, the vertical distance R between datum W1 and the datum line W2 maybe calculated by PLC. This can ensure that PLC knows where it needs toposition the erector head so that top panel A, and accordingly, datum W1are properly positioned throughout the processing of the blank by caseformer 1100.

Case former 1100 is able to track and modify the position of each caseblank as it is being processed, and in particular the vertical positionof the datum line W1 of the case blank as the case blank moveslongitudinally through case former 1100 and as various components ofcase former 1100 engage the case blank during its movements. This willensure that the case blank being processed is appropriately positionedrelative to the system components so that the system components engagethe case blank at the correct position on the blank during processing ofthe blank. For blanks that may be configured differently than blank 111,suitable adjustments may possibly be required to the dimensions anddatums maintained by PLC 132 in order for carton former 1100 to be ableto process a particular size/configuration/type of blank.

Labelling device 1281 may be mounted to the frame of carton/case former1100 in the vicinity of alignment conveyor 1206. For example (althoughnot depicted as such in the FIG. 57 for simplicity) labelling device1281 may be mounted to a frame portion of carton former 1100 generallyabove where a case blank is located when the case blank is in the pickup location. Labelling device 1281 may be operable to print and applyone or more labels to one or more panels, preferably upward facingpanels, of a blank located at the pick up location. Labelling device1281 may be any suitable device such as the PLS-500 label applicationsystem made by Paragon Labeling Systems Inc. (White Bear Lake, Minn.,USA) in conjunction with an integral print engine, such as a Lt408 printengine or a S84 Series print engine (e.g., model nos. S8408, S8412, orS8424) made by SATO America, Inc. (Charlotte, N.C., USA). While in someembodiments a labelling device may apply a physically separate label tothe case or case blank, in other embodiments the labelling device mayapply printing to the case or case blank without providing the printingon a physically separate label.

As noted above, the label or labels applied to an upward facing panel(s)of each blank by labelling device 1281 may be specifically configuredfor that particular blank and may contain various types of informationrelating to an order of products to be fulfilled for the case to beformed from that particular blank. The label or labels may containinformation providing certain order information including types ofproducts to be loaded into the case to be formed from that blank,optionally including product codes of those products, the customer towhom the case is to be shipped and the customer's address, as well as acase packing diagram that may be used by a product picker or filler inpacking the case in a desired configuration with the products, and thelocations in the warehouse building of the products. The label or labelsmay also contain a unique case identifier. Some or all of theinformation may be provided in bar code format, which a bar code readingdevice handled by an OFP may use to access the information form thelabel(s) once applied to the case blank.

The label is thus preferably printed and applied to the case blank whileit is in a flattened configuration at the pick up location and prior tobeing erected and bottom sealed. This may make the label applicationprocess more reliable and provides the case with a uniqueidentification.

Examples of the format of labels 1283 a, 1283 b that might be applied bylabelling device 1281 are illustrated in FIGS. 59 and 60 respectively.

Once the label has been applied by labelling device 1281, case former1100 may then proceed to erect and seal the case from the case blank ina manner like system 100 described above. It will be appreciated thatPLC 132 may be in communication with the labelling device 1281 and canprovide instructions for the printing and application of a suitablelabel or label(s) for the particular blank that is at the pick uplocation.

Once the case has been formed and sealed to form an erected case that ispartially sealed and may be in a configuration such as shown in FIG. 16,the case may then be delivered from the discharge conveyor 117 (see forexample FIG. 8) and be placed onto an accumulation conveyor that may bepart of the respective case loader such as case loader 1400A, 1400B or1400C associated with the particular carton former 1100A-C which formedthe case.

The OFP may initiate the order picking process by picking an empty casefrom an accumulation conveyor and place the case onto an OFP cart 1413(FIG. 62B) that can be moved around the warehouse where the productshandled by system 1100 are located. Multiple cases may be picked andplaced onto the OFP cart at the same time. The OFP will scan theappropriate bar code label on each case. This provides the OFP with allof the information necessary to pick and pack the order as predeterminedby order fulfilment processor 1300. In some instances, some of all ofthis information may be retrieved by the OFP from the PLC 132 of thecase former or from order fulfilment processor 1300 using a unique caseidentifier encoded in the bar code label.

With all of the order information available to the OFP the OFP picks andpacks the order of products directly into the case. The OFP may verifythat the correct products are being packed into the case by bar codereading both the product and the case during the picking and packingoperation, e.g., by comparing the UPC/ISBN provided by the bar code onthe label(s) applied to the case with the UPC/ISBN on the product beingpacked.

Once the order (or part order for a particular case) has been completedby the OFP, such that all products for that case are loaded into thecase, the case is directed to a final case sealing apparatus 1500A-C.For example the OFP may place the loaded case with all products loadedtherein onto a predetermined Random Top Case Seal (RTCS) in-feedconveyor that may feed the case to a suitable top sealing device. TheRTCS may be adapted to read a label on the case placed by labellingdevice 1281 or otherwise located on the case, and as a result ofinformation provided by the bar code the RTCS may automatically adjustthe sealing components of the device so that it may close and seal thetop of the case. The finished case may then be conveyed into the centralcase distribution system for further sorting and processing. An exampleof the type of suitable RTSC apparatus that could be employed as part ofsystem 1000 is the random case sealer made by Marq Packaging Systems.

In operation of system 1000, each one of a plurality of customers mayuse a customer order device such as devices 1200A, 1200B and 1200C,including possibly accessing call center 1250. Through operation ofappropriate software on the order placement devices 1200A-C, the orderplacement devices 1200A-C may communicate directly or indirectly withorder placement processor 1300 to so that multiple orders may be placedby customers, each orders being for one or more products, into orderfulfilment processor 1300.

Order fulfilment processor 1300 may process the customer orders receiveddirectly or indirectly from customer order devices 1200A-C. Orderfulfilment processor 1300 may for each order utilize its database thatincludes information that may be stored therein including informationrelating to: (a) details of all products that may be ordered by acustomer through system 1000 including the actual physical dimensions ofeach product (such as the dimensions of the item package in which anitem is packaged), optionally the weight of each product, and furtheroptionally product codes associated with each product; (b) details ofeach of a plurality of types/sizes/configurations of cases/case blanksthat can be used in system 1000 to package one or more products orderedby a customer including the dimensions of each case/case blank; (c)details of each case former (e.g., case formers 1100A-C), including thetypes of cases that each case former is capable of forming, andoptionally when a case former includes multiple magazines, the type ofcase blank provided in each of those magazines and the correspondingtype of case that can be formed from each type of case blank, andfurther optionally the quantity of case blanks provided in each of thosemagazines; (d) information about each customer including the name of theentity and shipping address to which an order fulfilled by system 1000is to be shipped; and (e) information about where each product islocated in a warehouse building housing products that may be ordered.

Order fulfilment processor 1300 may also for each order use the productpackaging utility to identify a suitable case and possibly an optimumcase (e.g. having particular type/size/configuration) from the packagingsuite of a limited and predetermined number oftypes/sizes/configurations of cases. Thus, when each order for specificproducts is input into order fulfilment processor 1300, the productpackaging utility can determine the optimal case or cases that can beused to package the products for each order (e.g. determine the leastnumber or cases and/or the smallest size of cases that are required topackage all the products in the customer order).

Order fulfilment processor 1300 may then for each order, generate aFulfilment Order data structure that may be communicated by acommunication link to the PLC of one of the case formers 1100A, 1100B or1100C. The order fulfilment processor 1300 may have determined to whichof the case formers to send each Fulfilment Order data structure eitherrandomly, or based on availability and/or suitability to handle the casetype/size/configuration determined for a particular customer order. TheFulfilment Order data structure may include information including (i)the type/size/configuration of case determined by the product packagingutility that is required to be formed and labelled by the case former1100A, 1100B, 1100C; (ii) the particular magazine of the case formercontaining case blanks for forming the required type/size/configurationof case; (iii) a list of the particular product(s) from the customerorder being fulfilled that are required to be loaded into the requiredcase once formed, optionally arranged in the order in which the productsshould be loaded into the case once formed; (iv) optionally a diagramillustrating a desired optimal physical arrangement of the product(s) inloading the case; (v) optionally the location in the warehouse buildingof each particular product from the customer order being fulfilled; and(vi) customer shipping information for that case indicating thedestination name and address for that case.

Each Fulfilment Order data structure may then be received and processedby the PLC 132 of the case former to which the data structure is sent.In particular, the PLC of the case former processes the Fulfilment Orderdata structure to identify the type/size/configuration of case (orcases) required, the particular magazine of the case former containingcase blanks for forming each required type/size/configuration of case,and the contents of the label (or labels) to be applied. Once a requiredtype/size/configuration of case and the particular magazine containingcase blanks for forming the required type/size/configuration of casehave been identified, the PLC of the case former causes a case blankfrom the identified magazine to be formed and labelled, generally asoutlined above.

In particular, the PLC activates the appropriate conveyor of magazineconveyors 1203(1) to 1203(16), corresponding to the identified magazine,if required to move a stack of case blanks of the identified typeadjacent to in-feed conveyor 1204. The transfer apparatus may, under thecontrol of PLC 132, then transfer the desired case blank from theidentified magazine to the in-feed conveyor 1204. The in-feed conveyor1204 will then under the control of PLC 132 move that case blanklongitudinally and then when signalled by PLC 132 to do so, transfer itto the alignment conveyor 1206.

Alignment conveyor 1206 also under the control of PLC 132 may then movethe case blank to the pick up location and PLC 132 may then also causethe side walls 1201, 1202, to transversely align the case blank so thatit is at the correct pick up position. PLC 132 may then cause labellingdevice 1281 to apply one or more labels like labels 1283 a, 1283 b toone or more upward facing surfaces of the panels of the case blank. PLC132 may then cause the carton forming components of the carton formerincluding an erecting head 120, to be moved by the movement sub-systemto pick up the case blank from the pick up position and erect andpartially seal the case from the case blank. PLC 132 may on an goingbasis, as each case blank is being processed, cause any adjustments incomponents of folding and sealing apparatus 130 to be made toaccommodate each case blank at they are processed.

Once the case has been formed and labelled for a particular customerproduct order, it may then be physically transferred to a respectivecase loader generally designated 1400A, 1400B or 1400C. The formed andlabelled case can be picked up by the OFP in a warehouse building filledwith the products. The OFP can scan and derive information from thelabel or labels applied to the case to identify the particular productsthat are to be loaded into that case and the OFP may then proceed tolocate the products in the warehouse and fill the case with thoseproducts, possibly in the order listed by the scanning device. Apackaging arrangement diagram either illustrated on the label on thecase, or optionally displayed on a device such as the label scanner, ifavailable, may be used by the OFP to load the case in the desiredoptimal manner.

Once the order (or part order for a particular case) has been completedby the OFP, such that all products for that case are loaded into thecase, the case is directed to a final case sealing apparatus 1500A-C.The OFP may place the loaded case with all products loaded therein ontoa predetermined Random Top Case Seal (RTCS) in-feed conveyor that mayfeed the case to a suitable top sealing device. The RTCS may read alabel on the case placed by labelling device 1281 or otherwise locatedon the case, and as a result of information provided by the bar code theRTCS may automatically adjust the sealing components of the device sothat it may close and seal the top of the case. The finished case maythen be conveyed into the central case distribution system for furthersorting and processing.

Various modifications are also possible in some embodiments. By way ofexample only, instead of providing for magazine conveyors 1203(1) to1203(N) for magazines M1 to M(N), it may be possible to provide for arobotic system which could extract case blanks as demanded by PLC 132from any one of a stack of case blanks in each of the magazines. Therobotic system could either place a particular case blank that may berequired on an in-feed conveyor. In other embodiments, the in-feedconveyor could be eliminated and the robotic system may place each caseblanks that is required at the pick up position.

Of course, the above described embodiments are intended to beillustrative only and in no way limiting. The described embodiments ofcarrying out the invention are susceptible to many modifications ofform, arrangement of parts, details and order of operation. Theinvention, rather, is intended to encompass all such modification withinits scope, as defined by the claims.

When introducing elements of the present invention or the embodimentsthereof, the articles “a,” “an,” “the,” and “said” are intended to meanthat there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.

1-112. (canceled)
 113. A method to facilitate fulfilling product orders,comprising: (a) queuing requests for cases of various sizes in a queuestored in an electronic memory; (b) accessing a next request from saidqueue; (c) determining a size for a case from said next request; (d)based on said size, automatically adjusting components of a case formingapparatus to adapt said case forming apparatus to form said case of saidsize; (e) transferring a case blank for said case of said size from aparticular repository to said case forming apparatus, said particularrepository holding case blanks for cases of said size; (f) operatingsaid case forming apparatus to form said case from said case blank; (g)until said queue is empty, repeating (b) to (f) for a request in saidqueue next following said next request.
 114. The method of claim 113wherein (d) comprises, based on said size of said case, setting aposition of an alignment component of a case blank alignment device sothat when said case blank abuts said alignment component, said caseblank has a predetermined position.
 115. The method of claim 114 whereinsaid alignment component is a first alignment component and wherein (d)further comprises, based on said size of said case, adjusting a strokeof a second alignment component opposed to said first alignmentcomponent.
 116. The method of claim 115 wherein said first alignmentcomponent is a laterally moveable first side guide for abutting a firstside of said case blank in order to set a predetermined lateral positionof said case blank and wherein said second alignment component is alaterally moveable second side guide for urging said case blank intoabutment with said first side guide.
 117. The method of claim 113further comprising, prior to (e), based on said size of said case,identifying from amongst a plurality of repositories of case blanks,each having case blanks of a different size such that any givenrepository has case blanks for cases of a single size, said particularrepository.
 118. The method of claim 113 wherein each said next requestcomprises a data structure, said data structure storing an indication ofsaid size for said case.
 119. The method of claim 118 furthercomprising, based on said size, adjusting a movement profile of a caseerecting component of said case forming apparatus.
 120. The method ofclaim 119 further comprising referencing said data structure andlabeling said case or said case blank with a label having informationfrom said data structure.
 121. The method of claim 120 wherein said datastructure stores an identification of products to be loaded into saidcase and an arrangement and packing order of said products to be loadedinto said case, and wherein said labeling comprises labeling such thatsaid label identifies said size of said case, said products to be loadedinto said case, and said arrangement and packing order.
 122. The methodof claim 117 further comprising automatically adjusting a position ofsealing components of a case sealing device to adapt said case sealingdevice to seal said case of said size.
 123. The method of claim 122wherein said case is labelled with a label indicating said size andfurther comprising reading said label to identify said size and whereinsaid adjusting said position of sealing components of said case sealingdevice is based on said case size read from said label.
 124. A systemfor use in fulfilling product orders, comprising: an electronic memoryfor holding a queue of requests, each request indicating a particularsize of a case; a case former having a plurality of adjustablecomponents each adjusted by a drive mechanism; a plurality ofrepositories for case blanks, each repository holding case blanks of adifferent size such that any given repository has case blanks for casesof a single size; a controller operatively associated with saidelectronic memory and electronically communicating with said case formerand each of said plurality of repositories, said controller operable to:(i) access said electronic memory to access a next request from saidqueue; (ii) determine a size for a case from said next request; (iii)based on said size, control each said drive mechanism to adapt saidadjustable components of said case former to operate on a case blank fora case of a size indicted by said next request; (iv) based on said size,control a particular repository to transfer said case blank for saidcase of said size from said particular repository; (v) control said caseformer to form said case from said case blank; and (vi) until said queueis empty, repeat (i) to (v) for a request in said queue next followingsaid next request.
 125. The system of claim 124 wherein said componentscomprise an alignment component of a case blank alignment device andsaid controller is operable to control said drive mechanism for saidalignment component so that when said case blank abuts said alignmentcomponent, said case blank has a predetermined position.
 126. The systemof claim 125 wherein each said next request comprises a data structure,said data structure storing an indication of said size for said case.127. The system of claim 126 wherein said alignment component is a firstalignment component and further comprising a second alignment componentopposed to said first alignment component and wherein said controller isoperable to control said drive mechanism for said second alignmentcomponent to adjust a stroke of said second alignment component. 128.The system of claim 127 wherein said first alignment component is alaterally moveable first side guide for abutting a first side of saidcase blank in order to set a predetermined lateral position of said caseblank and wherein said second alignment component is a laterallymoveable second side guide for urging said case blank into abutment withsaid first side guide.
 129. The system of claim 128 further comprising alabeller, wherein said controller is operably associated with saidlabeller and wherein said controller is further operable to referencesaid data structure and control said labeller to label said case or saidcase blank with a label including information from said data structure.130. The system of claim 128 wherein said data structure stores anidentification of said products to be loaded into said case and anarrangement and packing order of said products to be loaded into saidcase and wherein said controller controls said labeller to label saidcase such that said label identifies said size of said case, saidproducts, and said arrangement and packing order.
 131. The system ofclaim 124 wherein said controller is further operable to, based on saidsize of said case, adjust a movement profile of a case erectingcomponent.
 132. The system of claim 124 further comprising a casesealing device having a reader and adjustable sealing components, saidcase sealing device operable to read said size of said case andautomatically adjust a position of said adjustable sealing components toadapt said case sealing device to seal said case of said size.